Aramcoinspectionhandbook 150311084705 Conversion Gate01 PDF

Southern Area Corrosion Control
&
Inspection Division
INSPECTOR’S
HANDBOOK
Published:
First Draft: July 18, 1999.

Final Proof: September 8, 1999
Page 2 of 111
Handbook Team:
D. Boult SAPED/TSU Chairperson
A. Brodie SACCID Member
N. Smith SACCID Member
Gopal SACCID Member
A.K. Al Hamad SACCID Member
A.S. Al Kishi SACCID Member
Compiled by D. Boult ~ SAPED/TSU (Tel: 576-6147)
Approved
______________ _________
A.F. Al Shammari Date
General Supervisor SACCID
Page 3 of 111
Preface
This handbook is designed to give the field Inspector useful

information to carry out his work safely and efficiently. If
a conflict exists between this handbook and any National
code or Saudi Aramco standard, then the SAES or SAEP
must be deemed correct.
The information contained was taken from various sources

and publication and is as accurate as possible. It is the
responsibility of the User to check any information used for
official purposes.
Any inaccuracies or discrepancies should be reported to the

Unit Supervisor as soon as possible.
If there are any omissions or areas not covered give the

details to the Unit Supervisor for inclusion in the next
revision.
The Handbook Team.
Page 4 of 111
Table of Contents
1.0 Paints & Coatings
2.0 Inspection Reports
3.0 Hydrostatic Testing
4.0 Welding Procedures
5.0 Inspection Tools
6.0 Safety Guidelines
7.0 Piping
8.0 Conversion Factors
9.0 Inspection Terminology
10.0 Vessels
11.0 Fittings
12.0 Codes & Standards
13.0 Supports
14.0 Non Destructive Examination
Page 5 of 111
PAINTS & COATINGS
1.0 Paints & Coatings
Inspection Methods And Acceptance Criteria
8.1 General
This section gives the mandatory inspection methods and acceptance criteria
that shall be met before the FBE-coated welds can be put into service.
8.2 Visual Inspection
The Inspector shall verify that the surface preparation

requirements of paragraph 7.2 are met prior to the commencement
of preheating.
8.2.2 Thickness checks shall be made on each coated weld joint using an
approved, correctly calibrated magnetic dry film thickness gauge
(e.g. Microtest, Elcometer or equivalent). The instrument shall be
calibrated in accordance with SSPC PA-2.
A minimum number of 6 readings shall be taken on each field joint coating to

verify compliance with the thickness requirement in paragraph 7.3.5.1. The
readings shall include the weld seam.
8.2.3 On the first 5 joints of the job and twice each day thereafter, the
quality of cure shall be checked by maintaining a MEK soaked pad in
contact with the coating surface for one minute and then rubbing
vigorously for 15 seconds. There shall be no softening of the
coating or substantial color removal from the coating.
8.2.4 The finished coating shall have a uniform, glossy appearance and be
free of defects such as holidays, fish eyes, lumps, dry spray, sags
and runs.
100% of the coated girth weld surface area shall be holiday

detected, inspected, and repaired in accordance with the
procedures and equipment specified in SAES-H-200 for the mill-
applied FBE coating on the pipe. Holiday detection shall not be
Page 6 of 111
conducted if the surface temperature of the coated girth weld
area exceeds 88oC.
Patch Coating
The material for patch coating shall be supplied or approved by the

manufacturer of the powder epoxy coating. The patch coating
shall not be applied when the pipe surface temperature is less than
3 deg C above the dew point.
6.3 Repairs
6.3.1 Damaged FBE coating shall be repaired as follows:
6.3.1.1 Areas smaller than 1450 sq mm - use thermal melt sticks or an

epoxy-patching compound approved by the RSA.
6.3.1.2 Areas larger than 1450 sq mm and smaller than 0.2 sq m - use an
epoxy-patching compound approved by the RSA.
6.3.1.3 Areas larger than 0.2 sq m - use APCS-113.
6.3.1.4 The repair coating shall overlap the adjacent sound coating by at
least 13 mm. Coating application shall be according to the
Manufacturer's recommendations.
6.3.2 Damaged PE coating shall be repaired as follows:
6.3.2.1 Isolated holidays less than 150 mm in any direction - Use a heat
shrink patch approved by the RSA. An average of no more than 1
field patch per 12 meter joint shall be acceptable for any
consecutive 100 meters. Damage in excess of this shall be sleeved
in accordance with paragraph 6.3.2.2 or cut out in accordance with
paragraph 6.3.2.3. The patches shall overlap the adjacent, sound
coating by at least 50 mm.
6.3.2.2 Holidays larger than 150 mm in any direction (including close

spaced, individual holidays that cannot be covered by a single patch
Page 7 of 111
per paragraph 6.3.2.1) - Use a full encirclement heat shrink sleeve
approved by the RSA. The sleeve shall overlap the adjacent sound
coating by at least 50 mm. Where more than one sleeve is
required, the sleeves shall be overlapped by at least 50%. A total
of no more than 3 meters shall be sleeved in the field in any
consecutive 100 meters in mountain terrain or 1000 meters in
other terrain.
5.2.5 Internal coatings in dead-leg areas shall be holiday free.
5.3 Internal Coatings, Various Services
Categories Appr'd Coatings Syst Area to be Coated/

New Maint. Other Remarks
Constr.
5.3.1 Water APCS-103 APCS-103 APCS-100, 101, & 102

Potable APCS-100 APCS-102 must be certified suitable
APCS-101 APCS-2B for potable water services.
APCS-102
APCS-2B
5.3.2. Water Oil APCS-100 APCS-103 For APCS-2A the allowable

or Gas APCS-101 APCS-2A pH range is 5.0 to 12.0,
APCS-102 the maximum allowable
APCS-103 service pressure is 3445
KPa (ga) (500 psig), and
the maximum allowable
partial pressures of H (2)
S and CO (2) are each 345
KPa (abs) (50 psia).
Page 8 of 111
5.4 External Pipe Coatings, Cross-Country

New Constr. Maint. Other Remarks
5.4.1 Buried APCS-104 APCS-109 APCS-106 may only be

(Pipe Body) APCS-105 APCS-113 used in cases where
APCS-106 subsequent field bending
will not be required, e.g.,
cement-lined pipe.
APCS-113 may be used on

new construction to repair
damaged FBE, to coat
already cement-lined pipe,
and on short runs of pipe
(60 meters or less) that
will not require subsequent
bending.
5. 4. 2 Buried APCS-104 APCS-113 Use APCS-22 if the

(Field Girth APCS-110 APCS-107 surface is slightly damp or
Welds) APCS-111 APCS-109 has oil/salt contamination.
APCS-112 APCS-22 APCS-113 may be used on
new construction for tie-in
welds and for girth welds
on thrust-bored pipe.
5. 4. 3 Buried APCS-104 APCS-113 Use APCS-22 if the

Fittings, APCS-113 APCS-19B surface is slightly damp or
Appurtenances, APCS-19B APCS-22 has oil/salt contamination.
And Spool Pieces APCS-10 Tapewrap (APCS-107 or
APCS-23 APCS-109) is acceptable
for maintenance on
tapewrapped or P2-coated
lines.
Page 9 of 111
5. 4. 4 Buried APCS-104 APCS-113 On sleeved crossings, the
Road Crossings APCS-105 APCS-19B carrier pipe shall be
APCS-113 APCS-107 coated with APCS-104,
APCS-19B APCS-109 APCS-105, APCS-19B, or
APCS-113. The casing shall
be externally coated with
any of these systems or
with APCS-3.
5. 4. 5 Above Not Not

Ground Required Required
5. 4. 6 Buried See See Coat concrete anchors in

Anchors Comments Comments accordance with standard
drawing L-AA-036531.
Steel anchors shall be
coated with APCS-113,
APCS-22, or APCS-19B.
5.6 External Pipe Coatings, In-Plant

New Constr. Maint. Other Remarks
5. 6. 1 Buried (All See See Same as for cross-country
services except Remarks Remarks pipe.
insulated) Exceptions:
APCS-107 and APCS-109
shall not be used on buried
hydrocarbon lines on plot.
Page 10 of 111
5. 6. 2 Insulated APCS-104 Same as Applies to pipe that will be
(Cold System) APCS-2A new operated continuously or
APCS-10 Constructi intermiiently below
APCS-105 on atmopheric dew point.
APCS-108 Cover with polyurethane or
foam glass insulation. For
APCS-2A, contact RSA if
applied onto cold surfaces.
Use APCS17A or APCS-17B
for temperatures less than
minus 40 0C.
5. 6. 3 Insulated See See No coating needed where

(Hot System) Remarks Remarks continuous operating
temperatiures exceed 65
0
C and the facility is in
service at least 90% of
the time. Otherwise,
obtain coating
requirements from
responsible Technical
Orgaanization.
5. 6. 4 Mild APCS-4
Atmospheric APCS-6
Exposure APCS-26B
5. 6. 5 Industrial APCS-1A APCS-26A

and/or High APCS-1B APCS-26B
Humidity APCS-22 APCS-1B
Atmospheric APCS-26B APCS-1C
Exposure APCS-22
Page 11 of 111
5.2 Materials
5.2.1 Abrasive shall be kept dry and clean. Regardless of the type of
abrasive, the sulphate, chloride, and calcium carbonate content (if
any) shall not exceed the levels given in Appendix I of this
standard.
5.2.2 The use of reclaimed slag abrasives is prohibited. The use of

reclaimed garnet is permitted provided it meets the requirements
of para, 5.2.1 and an approved recycling system is utilized.
5.2.3 The use of sand as a blasting abrasive shall be permitted only as

follows:
5.2.3.1 The sand shall meet the requirements given in Appendix I of this
standard.
5.2.3.2 New construction, exterior surfaces. Sand meeting the

requirements of para. 5.2.3.1 shall be permitted for APCS-4,
APCS-6 and APCS-26. It is also permitted as a pre-blasting
medium for exterior surfaces to be subsequently re-blasted with
abrasive grit.
5.2.3.3 Spot repairs (Maintenance and New Construction) exterior

surfaces: Sand-meeting requirements of para. 5.2.3.1 shall be
permitted for maintenance/repairs to isolated areas not
exceeding 0.1 sq. meters and no more than 5% of the total area of
the structure is involved.
5.2.3.4 Sand shall not be used as a blasting abrasive for immersion

coatings. Exception: spot removal of existing coatings for
inspection purpose. The affected areas shall be re-blasted with
abrasive grit prior to recoating.
Page 12 of 111
Appendix I - Qualification Procedure For Sand For Abrasive Blasting
Prior to use, the Responsible Technical Organization shall certify in writing that the
sand meets the requirements below:
1. Physical characteristics: The sand shall be clean, dry, and free of

contaminants.
2. Composition: the sand shall contain more than 90% by weight silicon dioxide
and less than 2.3% by weight calcium carbonate.
3. Loss on ignition in accordance with ASTM C146: at 1000 deg C the sand shall
not lose more than 1% by weight.
4. Water solubles (1:1 extract): The abrasive shall be less than 250 ppm
sulfates and less than 250 ppm chlorides, in accordance with ASTM D516
Method B and D512 Method A respectively.
5. Profile: The anchor pattern created on mild steel plate at 620 kPa (90psi)
nozzle pressure during abrasive flow must be in accordance with the
specified requirements of the applicable APCS Data Sheet.
6. Appearance: No discernable contaminants shall remain on the steel substrate

when viewed through a5X Data Sheet.
A separate, new certification is required for each job. The Inspector may
require additional checks during the course of the job if, in his opinion,
conditions warrant it.
Table II - Calculating Dft, Wft, And Theoretical Coverage

Dry Film Thickness (DFT)
No solvent added: DFT = WFT x % Solids by Volume
% Solids by volume
Solvent added DFT = WFT x 1+ % thinner by volume
Theoretical Coverage
1000
Coverage (sq. m) = No. L X % Solids per L x DFT (micrometers)
1604
Coverage (sq. ft) = No. Gal coating X % Solids per L x
DFT (mils)
Page 13 of 111
Table I – Dew Point Calculation Chart Ambient Air Temperature
(Degrees Celsius)
Relative -7 -1 4 10 16 21 27 32 38 43 49
0 0 0 0 0 0 0 0 0 0 0
Humidity C C C C C C C C C C C
90 -8 -2 3 8 14 19 25 31 36 42 47
85 -8 -3 2 7 13 18 24 29 35 40 45
80 -9 -4 1 7 12 17 23 28 34 39 43
75 -9 -4 1 6 11 17 22 27 33 38 42
70 -11 -6 -1 4 10 16 20 26 31 36 41
65 -11 -7 -2 3 8 14 29 24 29 34 39
60 -12 -7 -3 2 7 13 18 23 28 33 38
55 -13 -8 -4 1 6 12 16 21 27 32 37
50 -14 -9 -5 -1 4 10 15 19 25 30 34
45 -16 -11 -6 -2 3 8 13 18 23 28 33
40 -17 -12 -8 -3 2 7 11 16 21 26 31
38 -19 -13 -9 -5 -1 4 9 14 18 23 28
30 -21 -16 -11 -7 -2 2 7 11 16 21 25
Example: if the air temperature is 21 deg. C the relative humidity is 70%,
the dew point is 16 deg. C.
Page 14 of 111
Sigma Phenguard Overcoating Times (Maximum Interval)
30
25
20
Time in Days
15
10
0
0 10 15 20 25 30 35 40 45 50
Temperature in Degrees C
Page 15 of 111
Sigma Phenguard Overcoating Times (Minimum Interval)
16
14
12
10
Time in Hours
8
0
0 10 15 20 25 30 35 40 45 50
Page 16 of 111
Sigma Phenguard Overcoating Times (Time to Immersion)
16
14
12
10
Time in Days
8
0
0 10 15 20 25 30 35 40 45 50
Page 17 of 111
Sigma Phenguard Times (Pot Life)
7
Time in Hours
4
0
0 10 15 20 25 30 35
Page 18 of 111
Sigma Phenguard Induction Time
25
20
15
Time in Hours
10
0
0 10 15 20 25 30
Page 19 of 111
SACCID Inspection
Reports
http://saoo.aramco.com.sa/data/saccid/saccid%20forms/GenlInsp/
SACPID-INSPECTION
INSP-9000
Ultrasonic Thickness Measurements
for Hot Tap/Sleeve Calculations
Plant Number: Plant Name: Date:
Equip./Line Number: System:

Description:
Ref: SAES-L-052, SAEP-311, Standard Drawing L-AB-036719
Equip./Pipe
Diameter Grade Schedule Flange Rating
Details:
Header
Branch per
Dwg.
Continuous Scanning
Measurement of Header in mm Min Max
1 Branch Centre -Point A. D E
2 Branch Diameter Circle B.
3 Reinforcing Pad Diameter Circle C. C A
B
4 Reinforcing Sleeve Ends -Line D-D
5 Reinforcing Sleeve Ends -Line E-E

D E
6 180 degree from Point A. Flow
Measurement on Header MIN: mm MAX: mm
Measurement on Sticker MIN: mm MAX: mm
Signed: Inspector Inspection Unit:
Note: For
Sleeve
connection
reinforcement
reinforcement
is required
requirements,
when the branch
referdiameter
to ASME is more
B31.3,than
B31.4,
70%B31.8,
of the header
ASME Section VIII & SA Standard Drawing L-AB-036719.
cc: Inspection File ____________
File: Abq5\Data\INSPFORM/INSP9000.XLS Page 20 of 111 Revised: 4/2/2002

SACPID-INSPECTION
INSP-9002
REQUEST FOR RADIOGRAPH, IN LIEU OF HYDROTEST
WAVER NUMBER (TO BE FILLED IN BY INSPECTION):
REFERENCE: DATE:
PLANT NO: SYSTEM #:
BI: JO: (If applicable)
ORIGINATOR'S NAME: DEPT/DIV:
JUSTIFICATION: (PLEASE INCLUDE A DESCRIPTION AND/OR SKETCH OF FACILITIES INVOLVED)
SIGNATURES REQUIRED: (RETURN APPROVED ORIGINAL WAIVER TO RESPONSIBLE INSPECTION UNIT)
1) ORIGINATOR:
2) UNIT SUPV., PLANT ENGG.
Please 3) OPERATIONS SUPT.:

sign as
numbered 4) SUPV., INSP. UNIT:
5) GEN. SUPV., SACPID:
6) MANAGER, OPERATIONS:
RADIOGRAPHS WILL BE INTERPRETED TO APPLICABLE CODE.

CONDITIONS OF APPROVAL
File: Abq5\Data\Inspfoorm\Insp9002.xls Revised: 4/2/2002

SACCID Date prepared: Revision 1 2 3 4
FACILITY EXCEPTION ITEM LIST Prepared by:

ARAMCO 6133-
T INSP-9003 Approved by: Date
PLT. Section: Subject:

Required Covered
Item No. Item Description for by Remarks
Startup Contract
10
11
12
13
14
15
16
abq5 on "a1ecc"/data/inspform/6133.xls jRevised: 11/28/98

SACCID
INSP-9006
LEAK REPAIR REPORT
(Fill in and/or encircle your choice)
Date Leak Reported: Plant Number: System:
Date Repair Started: SACPID/____.:
Date Repairs Completed: Date:
DATA
Equipment: Plant Name: On Plot: Yes / No
From:
To: Service: * ( Oil / Gas / Water / Sewer / Firewater/
Disposal / Chem. / Air / Seawater
Installation Date: (Year) N2 / SO2 / S / SO2 SOL
Material: * CS / SS / PVC / FRP / GI / CI/RTR Injection Water / Supply Water )
Nominal Diameter: (Inches)
Nominal Wall Thickness: (Inches) Restrained: Yes / No
INSPECTOR'S REPORT
LEAK INFORMATION
Leak Location:
Leak Position: Buried: Yes / No
Length / Dia.: HOLE " : Backfill Type: Sand / Subkah / Marl / Rocky
RUPTURE " :
CAUSE : * Corrosion / Erosion / Mechanical / Crack EXISTING COATING APPEARANCE
TYPE: * Internal / External Details:
Corrosion Form: * General / Pit / Lake / Bands/ Groove 1. * Smooth / Cracked / Damaged
2. * Adherent / Detatched
Data Base Comments: Coating Type: APCS -
I.
II.
Repair: ( Wood plug /Steel plug / Sleeve / Replaced / Weld Overlay/Patch )

NOTE: You may encircle more than one if necessary.
REPAIR DETAILS:
A.
B.
C.
INSPECTOR: FIELD SUPERVISOR:
Inspection File: APPR. FOR COMP. INPUT
* Choose One Only. SIGNED:
File: Abq5\Data\Inspform\Insp9006.xls Revised: 4/2/2002

SACCID
PRESSURE TEST REPORT
SAUDI ARAMCO 2642 INSP-9008 (Dec 00)
Reference Details:
Plant Name: Plant No: Insp. Unit: SACPID/
Equipment Description:
Location in Service: System #:
Shop Order: DWG No: SACPID Ref:
Verbal Report To: At:
[Contact Name & Position] [Date & Time]
Test Details:
Test Procedure in Initial Test Repair
Accordance with: Revalidation Modification
Preliminary Tests: Test Type:
[Hydro /Pneu/ Leak
Repairs During Tests: Test Fluid:
MAOP: Test Temp:
Relief Valve Tag #: Test Pressure:
Relief Valve Test Date: Test Duration:
Relief Valve Set Pressure: Test Date:
Pressure Gauge Cal Date: Gauge Range:
Sketch:
Test Results:
Accept: Reject: Conditional:
Comments:
Inspector: Field Supervisor:

Badge #: Badge #:
Date: Date:
C:\Data\Word\INSP-9008_Form_(Template).dot
SACCID
INSP-9009
RADIOGRAPHY REQUEST SHEET
Radiography Corrosion
Scale
PLANT NAME: AREA:

PLANT NO.: INSPECTOR: Date: __/ __/ __
[ ] ON PLOT INTERPRETER: Date: __/ __/ __
[ ] OFF PLOT SYSTEM #:
FILM SIZE
INDENT. LINE IDENTIFICATION DIA. x THKS TYPE* FINDINGS/REMARKS
* Type: 1. Offset Side Shot 3. Contact Side Shot File: ________________

2. Offset Bottom Shot 4. Contact Bottom Shot
Page 25 of 111
SACCID
INSP-9011
Ultrasonic Testing Inspection Report
Date:
Plant Name: Plant Number:

Equipment Name:
Size / Line # : System #: Pressure:
OSI DWG. # : Nominal Thk. : mm
U.T. Location : Retirement Thk. : mm
U.T Equipment: U.T. Measurement:
Probe Size: mm Min: mm Max: mm
Frequency: Mhz
Gain: db Technicians: Verified:
Range: mm
Description / Sketch:
Scale
______
Flow
12 12
1 1
2 2
3 3
4 4
5 5
CLOCK
6 6
POSITION
7 7
8 8
9 9
10 10
11 11
12 12
LENGTH
Page 26 of 111
SACCID
INSP-9013
FREQUENT INSPECTION FORM
Plant Name
Plant Number
System Number
Frequency Weekly Monthly 6 Monthly Yearly Other: Specify
Start Date
End Date
Letter Book#
Job
Remarks
Inspector
Field Supv.
Plant Name
Plant Number
System Number
Start Date
End Date
Letter Book#
Job
Remarks
Inspector
Field Supv.
Plant Name
Plant Number
System Number
Start Date
End Date
Letter Book#
Job
Remarks
Inspector
Field Supv.
cc: Supervisor
File: D:\DATA\INSPFORM\INSP9013 Revised: Dec. 1995
Page 27 of 111
SACCID
INSP-9014
VESSEL INSPECTION REPORT
Plant Name: Plant Number: Date: ____/____/____
VESSEL DATA
Vessel Name: Vessel Number: System #:
Length/Height: Diameter: Mat'l: Year Built:
Total Surface Area: T-Minimum: Shells: SIS Number:
Heads:
COATING DATA
Existing Type: Date Applied: Existing Dry Film Thk:
New Type: Date Applied: New Dry Film Thk:
ANODES
Old
Type: Number: % Consumed: Date Installed: ____/____/_____
Replaced: YES/NO New Type: Date Installed: ____/____/_____
REMARKS:
Recommendations:
Signed:
See reverse for vessel drawing Date: ____/____/_____
Page 28 of 111
SACCID
Aramco 4719-0 INSP-9030
ARAMCO INSPECTION PROCEDURES
LIQUID PENETRANT EXAMINATION REQUEST & REPORT SHEET
Log No. B.I. No. Job. No. Plant No. Plant Name Contractor
Location/Kilometer Reference Aramco Rep. Unit Requested by: Phone Date
Technician Date Acceptance Criteria Material Type Approved by (Proj. Insp.) Date
Sch/Wall ThicknPenetrant System Penetrant batch Penetrant Mfg. Penetrant Part No. Cleaner/Remover Part No.
A-3 ____ B-3 ____ Batch No:
Ultraviolet Light Used Measured UV light Intensity Developer Part No. Surface Condition
ITEM DRAWING EQUIPMENT NO/DIA/ SYSTEM WELD WELDER EXAM RESULTS REPAIR LOCATION COMMENTS
NO. NO. LINE REFERENCE NO. NO. SYMBOL ACC. REJ. AND DEFECT TYPE
DISTRIBUTION: Note 1: Comments include type of work examined.

1 New?, Repair?, Rework?, Tope of part if
2 not weld. etc.
3
4 Note 2: All blanks are to be listed in. If information in
5 particular blank is not applicable, write in N/a
Audited by: _________________________________________
Page 29 of 111
SACCID
INSP-9024
COATING SURVEY
PLANT # :
PLANT NAME :
SYSTEM # : DATE:
EXISTING COATING COATING FAILURE COATING REPAIR CORROSION WELD ANODES
EQUIP. YEAR SIZE % REPAIRS
# BUILT DIA L. AREA YEAR YEAR
COATED TYPE APPLIED % LOCATION TYPE COATED TYPE LOCATION DEPTH YES/NO TYPE #
Page 30 of 111
SACCID
INSP-9027
PIPELINE HYDROTEST DATA FORM
Plant Name: Plant Number:
Flowline/Trunkline Name: System Number:
Hydrotest Date: / /
Test Pressure: PSIG
MAOP: PSIG
Hydrotest Interval Year
Comments:
Inspector:
Field Supervisor:
Approved (Data Entry):
Page 31 of 111
SACCID
Aramco 4719-8 INSP-9031
ARAMCO INSPECTION PROCEDURES
MAGNETIC PARTICLE EXAMINATION REQUEST & REPORT SHEET
Log No. B.I. No. Job. No. Plant No. Plant Name Contractor
Location/Kilometer Reference Aramco Rep. Unit Requested by: Phone Date
Technician Date Acceptance Criteria Material Type Approved by (Proj. Insp.) Date
Sch/Wall Thick. Magnetic Particles, Mfg. Particle Color Wet Method Particles Part No. Particles Batch No.
or Dry?
Particle Size Power Supply Descrptn. & Mfg. Pwr. Sup. Model No. & Sl. No. Magnettizing Current:
Amps. _____ AC _____ DC _____
Prod or Probe Method Prod of Probe Mfg/Model No./Serial No. Demagnetization Performed? Yes ___ No___
Equipment and Method Used:
Surface Condition & Cleaning
ITEM DRAWING EQUIPMENT NO/DIA SYSTEM WELD WELDER EXAM RESULTS REPAIR LOCATION COMMENTS
NO. NO. LINE REFERENCE # NO. SYMBOL ACC REJ. AND DEFECT TYPE
DISTRIBUTION: Note 1: Comments include type of work examined.

1 New?, Repair?, Rework?, Type of part if
2 not weld. etc.
3
4 Note 2: All blanks are to be listed in. If information in
5 particular blank is not applicable, write in N/a
Audited by: _________________________________________
Page 32 of 111
SACCID
INSP-9035
Ultrasonic Testing Inspection Report
Date: _________________________
Plant Name: ______________ Palnt Number: _________ Plant Name: ______________ Palnt Number: _________
Equipment Name: _________________________________ Equipment Name: _________________________________
Size / Line #: ____________________________________ Size / Line #: ____________________________________
System #: _______________ Pressure: _____________ System #: _______________ Pressure: _____________
OSI DWG. #: ____________ Nominal Thk.: _____________mm OSI DWG. #: ____________ Nominal Thk.: _____________mm
U.T. Location: ____________ Retirement Thk: ____________mm U.T. Location: ____________ Retirement Thk: ____________mm
U.T. Equipment: ___________ U.T. Measurement: U.T. Equipment: ___________ U.T. Measurement:
Probe Size: _________mm Probe Size: _________mm
Frequency: _________Mhz Min: _____ mm Max: _____mm Frequency: _________Mhz Min: _______ mm Max: _______mm
Gain: _________db Gain: _________db
Range: _________mm Technicians: ________Verified: _______ Range: _________mm Technicians: ________Verified: _______
Description / Sketch: Description / Sketch:

Scale Scale
FLOW FLOW
12 12 12 12
1 1 1 1
2 2 2 2
3 3 3 3
4 4 4 4
CLOCK 5 5 CLOCK 5 5
POSITION 6 6 POSITION 6 6
7 7 7 7
8 8 8 8
9 9 9 9
10 10 10 10
11 11 11 11
12 12 12 12
LENGTH LENGTH
Equipment Name: _________________________________ Equipment Name: _________________________________
Size / Line #: ____________________________________ Size / Line #: ____________________________________
System #: _______________ Pressure: _____________ System #: _______________ Pressure: _____________
OSI DWG. #: ____________ Nominal Thk.: _____________mm OSI DWG. #: ____________ Nominal Thk.: _____________mm
U.T. Location: ____________ Retirement Thk: ____________mm U.T. Location: ____________ Retirement Thk: ____________mm
U.T. Equipment: ___________ U.T. Measurement: U.T. Equipment: ___________ U.T. Measurement:
Probe Size: _________mm Probe Size: _________mm
Frequency: _________Mhz Min: _____ mm Max: _____mm Frequency: _________Mhz Min: _______ mm Max: _______mm
Gain: _________db Gain: _________db
Range: _________mm Technicians: ________Verified: _______ Range: _________mm Technicians: ________Verified: _______
Description / Sketch: Description / Sketch:

Scale Scale
FLOW FLOW
12 12 12 12
1 1 1 1
2 2 2 2
3 3 3 3
4 4 4 4
CLOCK 5 5 CLOCK 5 5
POSITION 6 6 POSITION 6 6
7 7 7 7
8 8 8 8
9 9 9 9
10 10 10 10
11 11 11 11
12 12 12 12
LENGTH LENGTH
Page 33 of 111
SACCID
INSP-9036
CHANGE OF REVALIDATION HYDROTEST INTERVAL
Plant Name: Plant Number: Date:
Pipeline #: System Number:
Last Hydrotest Date: Initial Hydrotest: YES NO
Existing Hydrotest Interval: years Proposed Hydrotest Interval: years
Date of Next Hydrotest:
Justification Comments:
Originator
Supervisor, INSPECTION UNIT Supervisor, PLANT ENGINEERING
CONCURRENCE:
SUPT. PRODUCING OPERATIONS DIV.
Page 34 of 111
SACCID
COATING ENVIRONMENT RECORD SHEET
Plant Name: Plant Number: INSP-9038
AMBIENT TEMP. STEEL TEMP. RELATIVE DEW POINT

DATE TIME ºC ºC HUMIDITY ºC INSPECTOR
NOTES
1) Record the readings every two hours.

2) Coating shall not be applied if steel temperature is less than 10ºC or more than 50ºC.
3) Coating shall not be applied if steel temperature is less than 3ºC above the dew point (refer to Table I of SAES-H
Page 35 of 111
HYDROSTATIC
TESTING
3.0 Hydrostatic Testing
Types of Pressure Tests and Their Purposes
The following describes various types of pressure tests and their purposes.
Each test can either be a hydrostatic test or, if approved by the Chief
Inspection Engineer, a pneumatic test. As previously noted, pressure tests
will normally by hydrostatic.
Strength Test
A Strength Test is a pressure test at an internal pressure that is high
enough to verify the integrity of the piping and/or equipment for service at
the Maximum Allowable Operating Pressure (MAOP). During this test, the
equipment shall not be subject to impact. The test pressure shall be
maintained for a duration of not less than 30 minutes for piping and 60
minutes for exchangers.
A strength test is applied in the following cases:
• Before piping system is initially placed in service.
• After repairs or alterations have been made that affect the strength of
pressure containing parts, except as noted in SAES-A-004/SAES-L-56.
• At intervals as specified by Equipment Inspection Schedules.
Tightness Test
A Tightness Test is a pressure test, which is conducted at a reduced
pressure from the strength test pressure, and is done immediately after the
strength test. A tightness test only applies to cross-country pipelines,
boilers, and pneumatic tests. The pressure must be maintained long enough
to permit inspection of the entire system for leaks, and for at least 10
minutes in all cases.
Page 37 of 111
Leak Test
A Leak Test is a pressure test to demonstrate that there are no leaks in the
system at the test are normally conducted by Operations during start-up or
commissioning of the facilities, using approved plant procedures, and are
outside the scope of SAES-A-004.
System Test
A System Test is an in-situ strength test which is applied to a system that
is comprised of piping and other equipment that operate at one MAOP, as
limited by the weakest element in the system.
Service Test
A Service Test is a strength test for low-pressure utility services that is
conducted at the operating pressure with the service fluid.
Revalidation Test
A Revalidation Test is a pressure test, which is meant to prove the integrity
of buried cross-country pipelines. This test is conducted at the option of,
and at the intervals set by, the responsible operating organization.
Saudi Aramco Engineering Standard SAES-A-004 and the applicable
industry code provide test pressure requirements. The following sections
discuss test pressures for plant piping and cross-country pipelines.
The above was taken from the Saudi Aramco 1998 Engineering
Encyclopedia.
Page 38 of 111
Gauge Calibration
good for 1 month 12
R/V Calibration good

for 1 week 15
9
7
Gauge range 30% to 6
80% of test 13 14
pressure
12
12
5 11
8 16
1 4
2
1. Hand or reciprocating test pump
2. Union (TYP.)
3. Gate Valve (TYP.)
4. Check Valve.
5. Pressure Gauge with necessary valves and piping to release the pressure in the transition
piping between the valve on the mainline and pressure.
6. Relief valve by-pass-piping assembly when pressures exceed relief valve setting.
7. Pressure Relief Valve
8. Drain installed at 6.00 O’clock position on the mainline and preferably at the lowest point of
the line being tested. A hose should be installed to the drain valve and run clear of any
excavations to an improved dumping area.
9. Weld Neck, Raised Face, Ring Joint and Blind Flange (TYP.)
10. Vent with valve and piping assembly located at the high point of the piping network.
11. Plug Valve in an open position during a typical hydrotest of more than one component.
12. Spectacle plate illustrating an opening position during a hydrotest.
13. Weld Neck, Raised Face or Ring Joint companion flanges.
14. Calibrated pressure gauge and piping assembly for release of pressure following the mainline
liquid dump.
15. Calibrated pressure gauge liquid filled (Ethylene Glycol, thick liquid alcohol).
16. Water discharge and suction.
Page 40 of 111
HYRDROSTATIC TEST PRESSURES
FLANGE AND VALVE FLANGE AND VALVE BODY VALVE VALVE SEAT
BODY RATING TEST PRESSURE RATING TEST PRESSURE
150 450 150 315
300 1125 300 815
600 2225 600 1630
900 3350 900 2440
1500 5575 1500 4075
2500 9275 2500 6785
Page 41 of 111
WELDING
PROCEDURES
4.0 Welding Procedures
SAEP-1101 Refinery Pipe

Material Form Plate or Pipe
Base Metal Thickness Unlimited
Process SMAW
Base Material Carbon Steel (P1) & low alloy steels
(P3, P4, P5, P9, P11)
Positions All
Current Direct (DC)
Polarity Reverse (electrode +)
Weld Progression Uphill
Joint Type Single vee
Bevel Angle 60o (± 5o)
Root Face 1/16" (± 1/32")
Root Opening 1/8" (± 1/32")
Root Bead E6010 (1/8", 5/32")
Fill/Cap E7018 or E8018-C1 (1/8", 5/32")
Diameter Range 2.5" NPS & greater
Filler Metal
Root EXX10/11 (A5.1, A5.5)
Fill/Cap EXX15/16/18 (A5.1, A5.5)
SAEP-1102 Cross Country (Downhill/Stovepipe Welding)

Process SMAW
Base Material Carbon Steel (P1)
Positions All
Current Direct (DC)
Weld Progression Downhill
Root Face 1/16" (± 1/32")
Root Opening 1/16" (± 1/32")
Root Bead E6010 or E7010 (1/8", 5/32")
Fill/Cap E6010 or E7010 (1/8", 5/32")
Filler Metal
Root/Fill/Cap Exx10/11 (A5.1, A5.5)
SAEP-1103 Stainless Steel SMAW Welding

Process SMAW
Base Material Stainless steels (P8)
Positions All
Current Direct (DC)
Root Face 1/16" (± 1/32")
Root Bead E308, or 308L, E309, E310, E316
E316L (3/32", 1/8")
Fill/Cap E308, or 308L, E309, E310, E316
E316L (3/32", 1/8") can be used
Filler Metal:
Root/Fill/Cap EXXX-15/16 (A5.4 austenitic)
SAEP-1104 Stainless Steel SMAW Welding with Backing Ring

Process SMAW
Base Material Stainless steels (P8), nickel (P41)
Page 43 of 111
and Ni-based (P42-47) alloys to
themselves. Dissimilar metal welds
include: Ni-based alloys to carbon
steels, low alloy steels, stainless
steels, nickel and Monel alloys;
Monel alloys joined to carbon steels;
nickel joined to stainless steels; and
stainless steels joined to carbon
steels.
Positions All
Current Direct (DC)
Root Face None
Metal Backing Carbon steel backing strip
Root/Fill/Cap E308, 308L, E309, E310, E316 or
E316L (3/32", 1/8")
Filler Metal (Root/Fill/Cap):
Stainless Steels EXXX-15/16 (A5.4)
Nickel Alloys Ni-based (A5.11)
Dissimilar Welds Ni-based (A5.11)
SAEP-1105 Dissimilar Steels

Process SMAW
Base Material Nickel alloys (P4X) to themselves
and to carbon steels. Dissimilar
metal welds include: Ni-based alloys
to carbon steels, low alloy steels,
stainless steels, nickel and monel
Page 44 of 111
alloys; monel alloys joined to carbon
steels; nickel joined to stainless
steels; stainless steels to carbon
steels.
Positions All
Current Direct (DC)
Root Face 1/16" (± 1/32")
Metal Backing None
Root/Fill/Cap EniCrFe-3 (1/8", 5/32")
Filler Metal Ni-based (A5.11)
SAEP-1106 Aluminum GTAW (TIG Welding)

Base Metal Thickness 0.474" maximum
Process GTAW
Base Material Aluminum and aluminum alloys (P21,
P22, P23, and P25) to each other
Positions All
Current Alternating (AC)
Shielding Gas Argon (10-20 CFH)
Gas Backing Not required
Tungsten Electrode 1/8" 1/2-1% Zirconium oxide
Root Face None
Metal Backing Aluminum backing strip
Root/Fill/Cap ER4043 (1/8")
Page 45 of 111
Filler Metal ERXXXX, (5.10)
SAEP-1107 Stainless Steel (TIG Welding)

Process GTAW
Base Material Carbon steels (P1), low alloy steels (P3,
P4, P5, P9, & P11), stainless steels (P8)
only to themselves. And carbon & low
alloy steels to each other.
Positions All
Current Direct (DC)
Polarity Straight (electrode -)
Gas Backing Argon (2-5 CFH)
Tungsten Electrode 3/32" 2% Thoriated
Root Face 1/16" (± 1/32")
Metal Backing None
Root/Fill/Cap
Stainless steel ER308L (3/32") or ER309L ER316L
Carbon Steel ERXXS-X (A5.18)

Low Alloy Steel ERXX (X) S-X (X) (A5.28)
Stainless Steel ERXXX (A5.9)
Diameter Range 1" NPS and greater with no restrictions.
For the occasional job requiring welding
of butt joints less than (1") diameter, the
welder shall weld a 2G and 5G-test
coupon on the smallest job size diameter
Page 46 of 111
tubing. The OIU Inspector shall witness
the welding and the weld radiographed.
SAEP-1108 Small Bore Stainless Steel (TIG Welding)

Process GTAW
Base Material Nickel (P41) and Ni-based alloys (P42-47)
to themselves and to each other.
Dissimilar metal welds include Ni-based
alloys to carbon steels, low alloy steels,
stainless steels, nickel monel alloys;
Monel alloys joined to carbon steels;
nickel joined to stainless steels; and
stainless steels to carbon steels.
Positions All
Current Direct (DC)
Tungsten Electrode 3/32" 2% Thoriated
Root Face 1/16" (± 1/32")
Metal Backing None
Root/Fill/Cap ERNiCr-3 (3/32")
Filler Metal A5.14
Diameter Range 1" NPS and greater
Page 47 of 111
SAEP-1109 Aluminum (TIG Welding)
Process GTAW
Base Material Aluminum and aluminum alloys (P21, P22,
P23, P25) to each other
Positions All
Current AC (Alternating)
Tungsten Electrode 1/8" 1/2-1% Zirconium oxide
Root Face 1/16" (± 1/32")
Metal Backing None
Root/Fill/Cap ER4043 (1/8")
Filler Metal ERXXXX, (A5.10)
Diameter Range 2.5" NPS and greater
SAEP-1112 Small Bore Piping

Material Form Pipe
Process SMAW
Base Material Carbon Steel (P1)
Positions All
Current DC
Root Face 1/16" (± 1/32")
Metal Backing None
Root E6010 (3/32" or 1/8")
Page 48 of 111
Fill/Cap E7018 or E8018-C1 (3/32" or 1/8")
Filler Metal
Root EXX10/11 (A5.1, A5.5))
Fill/Cap EXX15/16/18 (A5.1, A5.5))
Diameter Range 1" NPS and greater
SAEP-1114 Plate Welding

Material Form Plate
Process SMAW
Base Material Carbon Steel (P1) and low alloys steels
(P3, P4, P5, P9, P11) to themselves and to
each other
Positions All
Current DC
Weld Progression Uphill except for the root bead which can
be run uphill or downhill
Root Bead Uphill or downhill (downhill progression
can only be performed with E6010)
(E7018 Uphill progression only)
Fill/Cap Uphill
Backside Arc gouged Uphill
Root Face 1/8" (± 1/16")
Metal Backing None
Root E6010 (3/16") or E7018 (1/8")
Fill/Cap E7018 (1/8" or 5/32")
Filler Metal
Root EXX10/11 (A5.1, A5.5)) or EXX15/16/18
(A5.1, A5.5)
Fill/Cap EXX15/16/18 (A5.1, A5.5)
Page 49 of 111
Weld Joint Preparation
Formula for Cross Section Area
Formula for Cross Section Area Formula for Cross Section Area CSA = RO x T
CSA = 1/2(S)2 CSA = 1/2(S1 x S2) RO
S
S
1
S S
T
2
Fillet Weld Fillet Weld

(Unequal Legs) Square
(Equal Legs)
Formula for Cross Section Area

CSA = (T - RF)2 tan A + RO x T Formula for Cross Section Area
2 A
CSA = 1/2(T - RF)2tan + RO x T
2
A
A
RF
RO RF
T
Single V
RO
Double V
The Fillet Weld

8
(1) BASE METAL: Metal to be welded.
(2) BOND LINE: The junction of the weld 5

metal and the base metal.
(3) DEPTH OF FUSION: The distance that fusion
extends into the base metal
(4) FACE OF WELD: The exposed surface of a weld on the 4

side from which the weld was done 2
(5) LEG OF FILLET WELD: The distance from the root of the joint
to the toe of the fillet weld.
The point or points, as shown in
(6) ROOT OF WELD:
crosssection,
at which the bottom of the weld intersects
the base metal surface or surfaces.
3
(7) THROAT OF FILLET WELD: The shortest distance from the root of 1
the fillet weld to its face. 7
6
(8) TOE OF A WELD: The junction between the face of a weld
and the base metal.
Page 50 of 111
ELECTRODES FOR WELDING SIMILAR AND DISSIMILAR METALS
Carbon Killed Carbon 304 SS 310 SS

Steel Steel Moly Cast Iron (18-8 Cr. (25-20 316 SS Inconel Incoloy Hastelloy
Steel Ni.) Cr.-Ni.) B
E6010 E7018 E7018 Certanium 1. E309 1. E309 1. E309 Inconel Inco A 1. Hast.
Carbon E7018 889 2. Inco A 2. Inco A 2. Inco A 182 B
Steel Ni-Rod 55 3. E310* 3. E310* 3. E310* 2.
Braze Inconel
(Oxweld 182
25M)
E7010 E7018 Certanium 1. E309 1. E309 1. E309 Inconel Inco A 1. Hast.
Killed 889 2. Inco A 2. Inco A 2. Inco A 182 B
Steel Ni-Rod 55 3. E310* 3. E310* 3. E310* 2.
Braze Inconel
(Oxweld 182
25M)
E7010 A1 Certanium 1. E309 1. E309 1. E309 Inconel Inco A 1. Hast.
Carbon (for plate) 889 2. Inco A 2. Inco A 2. Inco A 182 B
Moly E7010 A1 Ni-Rod 55 3. E310* 3. E310* 3. E310* 2.
Steel (for pipe Braze Inconel
only) (Oxweld 182
25M)
Certanium X X X Braze Braze X

Cast Iron 889 (Oxweld (Oxwel
Ni-Rod 55 25M) d 25M)
Braze
(Oxweld
25M)
Gas Weld
(Cast iron
filler rod)
E308 1. E309 1. E308 Inconel Inco A 1. Hast.
304 SS (18- 2. E308 2. E316 182 B
8) 2.
Cr. Ni. Inconel
182
3. E310
310 SS E310 1. E309 Inconel Inco A 1. Hast.
(25-20 Cr. 2. E316 182 B
Ni.) 2.
Inconel
182
3. E310
E316 Inconel Inco A 1. Hast.
316 SS 182 B
2.
Inconel
182
3. E310
Inconel Inco A Inco A
Inconel 182
1. Inco Inco A
Incoloy A
2.
E310*
1. Hast.
Hastello B
y
B
Page 51 of 111
ELECTRODES FOR WELDING SIMILAR AND DISSIMILAR METALS (Continued)
1-1/4% &
Hastelloy 3-1/2% 2-1/4% 5% 9% 12%
C Monel Brass Nickel Chrome Moly Chrome Moly Chrome Moly Chrome SS
Hast. C 1. Monel Braze 1. E7018 A 1. E7018 B 1. E7018 B 1. E9018 B3 B 1. Inco A A
Carbon 190 (Oxweld 2. Inco A A 2. E9018 B3 B 2. E9018 B3 B 2. E502 B 2. E310 A
Steel 2. Inco A 25M) 3. E8018 C2 A 3. E502 B 3. Murex 3. E410 B
4. E310* A Croloy 9A B
4. E310* A
Killed 190 (Oxweld 2. Inco A A 2. E9018 B3 B 2. E9018 B3 B 2. E502 B 2. E310 A
Steel 2. Inco A 25H) 3. E8018 C2 A 3. E502 B 3. Murex 3. E410 B
4. E310* A Croloy 9A B
4. E310* A
Carbon 190 (Oxweld 2. Inco A A 2. E9018 B3 B 2. E9018 B3 B 2. E502 B 2. E310 A
Moly 2. Inco A 25H) 3. E8018 C2 A 3. E502 B 3. Murex 3. E410 B
Steel 4. E310* A Croloy 9A B
4. E310* A
X Braze Braze Braze Braze Braze Braze Braze
Cast (Oxweld (Oxweld (Oxweld (Oxweld (Oxweld (Oxweld (Oxweld
Iron 25H) 25H) 25H) 25H) 25H) 25H) 25H)
1. Hast. C Inconel X 1. E309 A 1. E309 A 1. E309 A 1. E309 A 1. Inco A A

304 SS 2. Inconel 182 2. Inco A A 2. Inco A A 2. Inco A A 2. Inco A A 2. E310 A
(18-8 182
Cr. Ni.) 3. E310
(25-20 182
Cr. Ni.) 3. E310
Page 52 of 111
1-1/4% &
Hastelloy 3-1/2% 2-1/4% 5% 9% 12%
C Monel Brass Nickel Chrome Moly Chrome Moly Chrome Moly Chrome SS
182
3. E310
Inco A Inconel Braze 1. Inco A A Inco A A Inco A A Inco A A 1. Inco A A
Inconel 182 (Oxweld 2. E310 A 2. E310 A
25H)
Inco A Inconel Braze 1. Inco A A Inco A A Inco A A Inco A A 1. Inco A A
Incoloy 182 (Oxweld 2. E310 A 2. E310 A
25H)
Hast. B 1. Monel X Hast. B A 1. Hast. B A X X X
Hastelloy 190 2. Inco A A
B 2. Inco A
Hast. B 1. Monel X Hast. B A 1. Hast. B A X X X
Hastelloy 190 2. Inco A A
C 2. Inco A
Monel Braze 1. Monel A Inco A A X X X
Monel 190 (Oxweld 190
25H) 2. Inco A A
Braze X X X X X
Brass (Oxweld
25H)
3-1/2% 1. E8018 C2 B X X X X
Nickel 2. Inco A A
E9018 B3 B 1. E9018 B3 B 1. E9018 B3 B Inco A A
1-1/4% & 2. E502 B 2. E502 B
2-1/4% 3. E310* B 3. Murex
Chrome Moly Croloy 9A B
4. E310* B
E502 B 1. E502 B Inco A A
5% 2. Murex
3. E310* B
1. Murex Inco A A
9% Croloy 9A B
2. E310* B
12% 1. E410 B
Chrome SS 2. Inco A A
3. E310* B
Page 53 of 111
1-1/4% &
3-1/2% 2-1/4% 5% 9% 12%
Monel Brass Nickel Chrome Moly Chrome Moly Chrome Moly Chrome SS
Monel Braze 1. Monel A Inco A A X X X
Monel 190 (Oxweld 190
25H) 2. Inco A A
Braze X X X X X
Brass (Oxweld
25H)
3-1/2% 1. E8018 C2 B X X X X
Nickel 2. Inco A A
E9018 B3 B 1. E9018 B3 B 1. E9018 B3 B Inco A A
1-1/4% & 2. E502 B 2. E502 B
2-1/4% 3. E310* B 3. Murex
4. E310* B
E502 B 1. E502 B Inco A A
5% 2. Murex
3. E310* B
1. Murex Inco A A
9% Croloy 9A B
2. E310* B
12% 1. E410 B
Chrome SS 2. Inco A A
3. E310* B
Page 54 of 111
Page 55 of 111
Page 56 of 111
INSPECTION TOOLS
5.0 Inspection Tools
The following is a list of some auxiliary items that can be used to assist in
conducting an effective visual inspection.
• Standard forms/inspection checklist
This item includes the Saudi Aramco EIS form, if appropriate; as well as any
other approved procedural checklists.
• Notebook and pencil

Use a notebook and pencil to write down observations at the time they are
made rather than attempting to recall them later.
• Original designs and data from earlier inspections
Refer to new or previously noted conditions in order to distinguish between
deviations and normal or desired conditions. Notes and photographs or
drawings from earlier inspections can be useful in making decisions about
current conditions.
• Cleaning tools
When needed, use simple cleaning tools such as a scraper or steel brush to
clean a surface before making a preliminary visual inspection. Chalk or similar
marking device. Use marking materials such as chalk to identify potential or
suspected problem areas.
• Straight ruler, square, and level

Use these items to measure problem areas and record the results for use in
follow-up inspections or treatments.
• Vernier, micrometer, and measuring tape

Use these simple measuring tools to determine and record material
thicknesses, a key indicator of corrosion.
Visual inspections can include both external and internal surfaces of

equipment. Internal surfaces, especially, are often inaccessible and require
the use of special inspection tools. In addition to the auxiliary items listed
earlier, the following tools can be used to gather and record data during
visual inspections.
Page 57 of 111
• Fiber Optics
• Pit Gauges
• Cameras
• Mirrors
• Magnets
The uses, advantages, and limitations of each of these instruments will be
discussed in depth later in this module.
Visual Details of Corrosion Types
Pit Gauges
Description/Operation. Pit gauges are instruments used to measure the
depth of pitting by placing a calibrated rod in the pit.
Application. Pit gauges are used to access the severity of localized
corrosion pitting. They can be used to measure the depth and width of a
depression or cavity in a pitted metal surface. The distribution of the attack
and an indication of the rate of corrosion can be determined by using these
tools.
Page 58 of 111
Advantages and Limitations. Pit gauges are relatively simple to use and the
data gathered by using them is easily interpreted. These tools can be used
to measure the depth of pitting on any accessible surface.
Mirrors
Description/Operation. To handle a variety of circumstances, mirrors of
varying sizes should be available, from a small dentist-style mirror for small
openings too much larger mirrors for larger exterior surfaces. Miniature
light sources can be attached to mirrors in order to illuminate dark areas.
Application. Mirrors can be used to observe inaccessible areas such as the
external surfaces of pipelines that are near the ground or a wall. They can
also be used to inspect the underside of a pipe that is difficult to see.
In addition, mirrors can be used to look around corners or through small
openings.
Advantages and Limitations. The advantages of mirrors include the fact
that they are simple to “operate” and easy to use. They are also inexpensive.
Their greatest limitation is the fact that, although mirrors are an effective
tool for close-up observation, their usefulness is limited to short-range
viewing.
Magnets
Application. Magnets can assist in identifying the individual material
composition of a piece of equipment by checking the magnetic properties.
Since only a few metals are easily identified by visual observation alone, a
magnet can be used to distinguish, for example, between magnetic types of
steel and nonmagnetic stainless steel and other alloys.
Advantages and Limitations. Magnets provide a simple, easy, and
inexpensive means of identifying certain types of metal. This simplicity is
also a limitation since the use of magnets as an inspection tool is limited to
this single application.
Page 59 of 111
6.0 Safety Guidelines
Basic Safety Precautions
Burn Protection
Molten metal sparks, molten slag, and welding, cutting and other
related processes produce hot metal surfaces. Serious burns can
occur if correct precautionary measures are not taken.
Appropriate footwear, clothing and eye protection should be used.
Fumes & Gases

Many welding, cutting and related processes produce fumes and
gases, which may be harmful to health. Avoid breathing arc-
welding fumes at all times. When inspecting welding in a confined
area, ensure there is an adequate ventilation system.
Radiation Burns
Arc welding produces ultra-violet and infrared radiation rays,
which will severely burn exposed eyes and skin. Always wear
protective clothing and eye protection to protect the skin and eyes
from radiation burns.
Electrical Hazards
Electric shock can kill. However, it can be avoided if the correct
safety precautions are practiced. Never touch live electrical
parts. The manufacturer's instructions and recommended safe
practices should be read and understood. Faulty installation,
improper grounding and incorrect operation and maintenance of
electrical equipment are all sources of danger.
Page 60 of 111
PIPING
7.0 Piping
ANSI B36.10Welded and Seamless Wrought Pipe
Nominal Out
Pipe Side Sched Sched Sched Stand Sched Sched
Size Diam. 10 20 30 ard 40 60
1 1.315 - - - 0.133 0.133 -
2 2.375 - - - 0.154 0.154 -
2½ 2.875 - - - 0.203 0.203 -
3 3.5 - - - 0.216 0.216 -
3½ 4.0 - - - 0.226 0.226 -
4 4.5 - - - 0.237 0.237 -
5 5.563 - - - 0.258 0.258 -
6 6.625 - - - 0.280 0.280 -
8 8.625 - 0.250 0.277 0.322 0.322 0.406
10 10.75 - 0.250 0.307 0.375 0.365 0.500
12 12.75 - 0.250 0.330 0.375 0.406 0.562
14 14.0 0.250 0.312 0.375 0.375 0.438 0.594
16 16.0 0.250 0.312 0.375 0.375 0.500 0.656
18 18.0 0.250 0.312 0.438 0.375 0.562 0.750
20 20.0 0.250 0.375 0.500 0.375 0.594 0.812
22 22.0 0.250 0.375 0.562 0.375 - 0.875
24 24.0 0.250 0.375 - 0.375 0.688 0.969
26 26.0 0.312 0.500 0.625 0.375 - -
28 28.0 0.312 0.500 0.625 0.375 - -
30 30.0 0.312 0.500 0.625 0.375 - -
32 32.0 0.312 0.500 0.625 0.375 0.688 -
34 34.0 0.312 0.500 0.625 0.375 0.688 -
36 36.0 0.312 0.500 0.625 0.375 0.750 -
38 38.0 - - - 0.375 - -
40 40.0 - - - 0.375 - -
Page 61 of 111
ANSI B36.10Welded and seamless Wrought Pipe
Nominal Out
Pipe Side Extra Sched Sched Sched Sched XX
Size Diam. Strong 80 100 120 160 Strong
1 1.315 0.179 0.179 - - 0.250 0.358
2 2.375 0.218 0.218 - - - 0.436
2½ 2.875 0.276 0.276 - - 0.375 0.552
3 3.5 0.300 0.300 - - 0.438 0.600
3½ 4.0 0.318 0.318 - - - -
4 4.5 0.337 0.337 - 0.438 0.531 0.674
5 5.563 0.375 0.375 - 0.500 0.625 0.750
6 6.625 0.432 0.432 - 0.562 0.719 0.864
8 8.625 0.500 0.500 0.594 0.719 0.906 0.875
10 10.75 0.500 0.594 0.719 0.844 1.125 1.000
12 12.75 0.500 0.688 0.844 1.000 1.312 1.000
14 14.0 0.500 0.750 0.938 1.094 1.406 -
16 16.0 0.500 0.844 1.031 1.219 1.594 -
18 18.0 0.500 0.938 1.156 1.375 1.781 -
20 20.0 0.500 1.031 1.281 1.500 1.969 -
22 22.0 0.500 1.125 1.375 1.625 2.125 -
24 24.0 0.500 1.219 1.531 1.812 2.344 -
26 26.0 0.500 - - - - -
28 28.0 0.500 - - - - -
30 30.0 0.500 - - - - -
32 32.0 0.500 - - - - -
34 34.0 0.500 - - - - -
36 36.0 0.500 - - - - -
38 38.0 0.500 - - - - -
40 40.0 0.500 - - - - -
Page 62 of 111
Plant Piping
• Unless limited by flanges or by valves in the line, the hydrostatic strength-
test pressure shall be calculated to produce a hoop stress of 90% of the
specified minimum yield strength (SMYS), but shall not be less than the
minimum test pressure that is determined per ASME/ANSI B31.3. For new
installations, the test pressure shall be calculated based on nominal pipe wall
thickness less mill tolerance (manufacturer's minus tolerance). Strength
test pressures for existing piping shall be per ASME/ANSI B31.3, based on
the design pressure.
• Based on ASME/ANSI B31.3, Paragraph 345.4, for hydrostatic leak tests,
the hydrostatic test pressure at any point in a metallic piping system shall
be as follows:
(a) Not less than 1-1/2 times the design pressure.
(b) For design temperatures that are above the test temperature, the
minimum test pressure shall be calculated as follows, except that the value
of ST /S shall not exceed 6.5:
1.5 PS T
PT =
S
where: PT = Minimum hydrostatic test gauge pressure.
P = Internal design gage pressure.
ST = Allowable stress at test temperature.
S = Allowable stress at design temperature.
(c) If the test pressure as defined above would produce a stress in excess
of the yield strength at test temperature, the test pressure may be
reduced to the maximum pressure that will not exceed the yield strength at
test temperature.
• Pneumatic strength tests, when approved, shall be conducted per Paragraph
345.5 of ASME/ANSI B31.3. The tightness test shall be per Paragraph
345.5.4 of ASME/ANSI B31.3. Only during the tightness test shall the
piping be approached and inspected for leakage
Based on ASME/ANSI B31.3, Paragraph 345.5, for pneumatic leak tests, the
test pressure is 110% of the design pressure.
• Underground pressure piping that is in process water service and employs
non-welded girth joints (bell and spigot) shall be strength tested to 1.5
times the system design pressure prior to backfilling. The test pressure
shall be maintained for two hours while the joints are inspected for leakage.
Page 63 of 111
If for operational safety reasons the line must be back-filled, then the
joints shall remain exposed during testing, or be subjected to a 24-hour
recorded test.
• Lube and seal oil piping shall be strength tested with the service fluid. The
test pressure shall be 1.5 times the design pressure or 690 kPa (ga) (100
psig), whichever is greater.
• Low-pressure lines that are designed for less than 690 kPa (ga) (100 psig)
may be pneumatically strength tested. The pneumatic strength test shall be
the lesser of 110% of the design pressure or 125% of the normal operating
pressure, but never less than 170 kPa (ga) (25 psig). A tightness test at 21-
35 kPa (ga) (3-5 psig) shall be conducted and the piping checked for leakage
with a soap solution.
• Instrument take-off piping and sampling system piping, up to the first
block valve, shall be strength tested with the piping or equipment to which it
is connected.
• Instrument lead lines, between the first block valve and the instruments to
which they are connected, shall be subjected to the same strength test as
the piping or equipment the instruments are connected to. Elements that
may be damaged shall be disconnected.
• Piping systems in vacuum service shall be strength tested to 100 kPa (ga)
(15 psig)
Paragraph 345.4.3 of ASME/ANSI B31.3 states that for a hydrostatic test

of piping with vessels as a system:
(a) Where the test pressure of piping attached to a vessel is the same as or
less than the test pressure for the vessel, the piping may be tested with the
vessel at the piping test pressure.
(b) Where the test pressure of the piping exceeds the vessel test pressure,
and it is not considered practical to isolate the piping from the vessel, the
piping and the vessel may be tested together at the vessel test pressure,
provided the owner approves and the vessel test pressure is not less than
77% of the calculated piping test pressure.
Page 64 of 111
Cross-Country Pipelines
• Unless limited by flanges or valves in the line, hydrostatic strength test
pressure of newly constructed pipelines shall be calculated to produce a hoop
stress of 90% of the SMYS of the pipe material based on the nominal wall
thickness. The test pressure at the lowest point of the pipeline, including
the static head, shall not result in a hoop stress greater than the
SMYS. The strength test pressure shall be maintained for two hours.
• The strength test temperature shall not result in a combined longitudinal
stress exceeding the SMYS. The combined longitudinal stress is calculated
based on 0.7 hoop stress at the test pressure plus temperature stress plus
bending stress.
• Tightness test of newly constructed pipelines shall be conducted at 95% of
the strength test pressure immediately at the completion of the strength
test. The tightness test pressure shall be maintained long enough for the
inspector to examine all exposed joints. A 24-hour recorded tightness test
shall be applied when the pipeline is buried or covered by insulation, or is
partially buried with a total buried length of more than 300 m (1000 ft).
• Where pressure variations caused by test-water temperature changes can
occur, such as in cross-country pipelines, a sufficient number of
thermocouples shall be installed to obtain accurate pipe metal temperature
measurements that are required in order to determine the acceptance of
the pressure test. The Consulting Services Department shall be consulted
with regard to any deviations that are noted in the 24-hour pressure chart.
Strength test pressure of existing pipelines shall be per the applicable

ASME/ANSI B31.4 or B31.8 piping code based on the Maximum Allowable
Operating Pressure (MAOP) of the pipeline. This is specified as follows:
(a) Portions of piping systems to be operated at a hoop stress of more than
20% of the specified minimum yield strength of the pipe shall be subjected
at any point to a hydrostatic proof test equivalent to not less than 1.25
times the internal design pressure at that point for not less than four hours.
When lines are tested at pressures which develop a hoop stress, based on
nominal wall thickness, in excess of 90% of the specified minimum yield
strength of the pipe, special care shall be used to prevent overstrain of the
pipe.
Page 65 of 111
P T = 1.25PD
where: PD = MAOP of limiting component.

(1) Those portions of piping systems where all of the pressured components
are visually inspected during the proof test to determine that there is no
leakage require no further test. This can include lengths of pipe, which are
pre-tested for use as replacement sections.
(2) On those portions of piping systems not visually inspected while under
test, the proof test shall be followed by a reduced pressure leak test
equivalent to not less than 1.1 times the internal design pressure for not less
than four hours.
(b) API RP 1110, Pressure Testing of Liquid Petroleum Pipelines, may be used
for guidance for the hydrostatic test.
(c) The hydrostatic tests shall be conducted with water, except liquid
petroleum that does not vaporize rapidly may be used provided:
(1) The pipeline section under test is not offshore and is outside of cities
and other populated areas, and each building within 90 m (300 ft.) of the
test section is unoccupied while the test pressure is equal to or greater than
a pressure which produces a hoop stress of 50% of the specific minimum
yield strength of the pipe;
(2) The test section is kept under surveillance by regular patrols during test;
and
(3) Communication is maintained along the test section.
(d) If the testing medium in the system will be subject to thermal expansion
during the test, provisions shall be made for relief of excess pressure.
Effects of temperature changes shall be taken into account when
interpretations are made of recorded test pressures.
(e) After completion of the hydrostatic test, it is important in cold
weather that the lines, valves, and fittings be drained completely of any
water to avoid damage due to freezing.
The above was taken from the Saudi Aramco Engineering Encyclopedia
Page 66 of 111
Page 67 of 111
Plidco Split Sleeves
Plidco split sleeves are used to:
• Permanently repair small splits, holes, or ruptures which cannot be plugged
or patched readily and where downtime for draining oil from a line is
excessive.
• Provide quick, temporary repairs without welding on urgently required

pipelines, which can be removed from service later for permanent repairs.
• Provide temporary repairs to process lines within plant limits where

economically justified. However, in these cases, sleeve pressure and
temperature limitations must be considered, and the sleeve must be removed
for permanent repair in approximately three months. As referenced in
Figure 6, the split sleeve halves are positioned around the pipe such that the
leak is located between the two rings of packing. When the sleeves are
bolted, the packing is compressed against the pipe surface, which contains
the leak. Plidco split sleeves are high in cost compared to other methods of
repair. Therefore, their use should be restricted to those cases where
speed of repair will provide sufficient economic justification SAEP-311
contains installation instructions, and pressure and temperature limitations
for split sleeves. Split sleeves cannot be used to connect two sections of
pipe.
HOT TAPS
Inspection Requirements
The engineer responsible for inspection must do the following:
• Inspect weld areas, and 50 mm (2 in.) on each side of them, using
continuous ultrasonic examination to determine minimum pipe wall thickness.
The measured thickness must be at least that calculated for the hot tap
conditions, and no less than 5 mm (0.2 in.).
• Identify laminations, cracks or any discontinuities in the area.
• Approve welding procedure.
• Inspect connection before and during installation for compliance with
specification.
Page 68 of 111
• Confirm that hydrostatic test pressure conforms to that specified.
• Witness and approve the hydrostatic test of equipment and connection.
• Confirm that the connection is opened, drained, and vented after
completing hydrostatic test.
• Inspect the removed coupon. Evaluate the extent of header internal
corrosion and verify wall thickness.
Testing Requirements
The engineer responsible for testing must apply the following test
requirements:
• The hot-tap machine must be periodically pressure tested based on GI
441.010 requirements.
• The hot-tap valve shall be pressure tested prior to installation.
• Pressure test the branch-to-pipe weld, and then pressure test the final
branch assembly.
• The reinforcing pad of a welded branch shall be tested with air at 173 kPa
(25 psig) through a tapped vent hole.
• The pressure for the test of the hot-tap connection shall be 1.5 times the
system design pressure (1.25 times for cross-country pipelines), however,
not to exceed the following: - The design hydrostatic test pressure of the
pipe or vessel being hot tapped, or - The minimum pressure in the pipe or
vessel being hot tapped, while the test is in progress, plus a calculated
differential pressure. The differential pressure shall be 1.25
times the allowable external pressure calculated per the ASME Code
Section VIII Division 1. The length, L, that is used in this calculation shall be
the total length of a split tee, or the inside diameter of the welded nozzle,
based on the actual design detail used.
• The test pressure of the hot-tap connection may be lower than the original
hydrostatic test pressure. This is acceptable since the purpose of the test
is to provide some assurance of the integrity of the connection weld, not a
proof test of the weld. The system being tapped need not be down rated if a
lower test pressure is used at a hot-tapped connection.
Page 69 of 111
Page 70 of 111
CONVERSION
FACTORS
8.0 Conversion Factors
FRACTION OF INCH DECIMAL INCHES MILLIMETERS
1/64 0.016 0.397
1/32 0.031 0.794
3/64 0.047 1.191
1/16 0.063 1.587
5/64 0.078 1.984
3/32 0.094 2.381
7/64 0.109 2.778
1/8 0.125 3.175
9/64 0.141 3.572
5/32 0.156 3.969
11/64 0.172 4.366
3/16 0.188 4.762
13/64 0.203 5.159
7/32 0.219 5.556
15/64 0.234 5.953
1/4 0.250 6.350
17/64 0.266 6.747
9/32 0.281 7.144
19/64 0.297 7.540
5/16 0.313 7.937
21/64 0.328 8.334
11/32 0.344 8.731
23/64 0.359 9.128
3/8 0.375 9.525
25/64 0.391 9.922
13/32 0.406 10.319
27/64 0.422 10.715
7/16 0.438 11.112
29/64 0.453 11.509
15/32 0.469 11.906
31/64 0.484 12.303
1/2 0.500 12.700
Page 71 of 111
33/63 0.516 13.097
17/32 0.531 13.494
35/64 0.547 13.890
9/16 0.563 14.287
37/64 0.578 14.684
19/32 0.594 15.081
39/64 0.609 15.478
5/8 0.625 15.875
41/64 0.641 16.272
21/32 0.656 16.668
43/64 0.672 17.065
11/16 0.688 17.462
45/64 0.703 17.859
23/32 0.719 18.256
47/64 0.734 18.653
3/4 0.750 19.050
49/64 0.766 19.447
25/32 0.781 19.843
51/64 0.797 20.240
13/16 0.813 20.637
53/64 0.828 21.034
27/32 0.844 21.431
55/64 0.859 21.828
7/8 0.875 22.225
57/64 0.891 22.621
29/32 0.906 23.018
59/64 0.922 23.415
15/16 0.938 23.812
61/64 0.953 24.209
31/32 0.969 24.606
63/64 0.984 25.003
1 1.000 25.400
Page 72 of 111
ENGLISH TO METRIC
TO CHANGE TO MULTIPLY BY
Inches Millimeters 25.4
Inches Centimeters 2.54
Inches Meters 0.0254
Feet Meters 0.3048
Miles Kilometers 1.609347
Square Inches Square Centimeters 6.452
Square Feet Square Meters 0.0929
Cubic Inches Cubic Centimeters 16.3872
U.S. Gallons Liters 3.7854
Pounds Kilograms .45359
Ounce Avoir Grams 28.3495
BTU Calories 252
METRIC TO ENGLISH
Millimeters Inches .03937
Centimeters Inches .39371
Meters Inches 39.371
Meters Feet 3.281
Kilometers Miles .62137
Square Centimeters Square Inches .1550
Square Meters Square Feet 10.7649
Cubic Centimeters Cubic Inches .061
Cubic Meters Cubic Feet 35.314
Liters U.S. Gallon .26417
Kilograms Pounds 2.20462
Grams Ounces Avoir .03527
Calories BTU .003968
Page 73 of 111
MEASURE
Cubic Feet Cubic Inches 1728
Cubic Inches Cubic Feet .00058
Cubic Feet Gallons 7.480
Gallons Cubic Feet .1337
Cubic Inches Gallons .00433
Gallons Cubic Inches 231
Barrels Gallons 42
Gallons Barrels .0238
Imperial Gallons U.S. Gallons 1.2009
U.S Gallons Imperial Gallons .8326
Square Feet Square Inches 144
Square Inches Square Feet .00695
Long Tons Pounds 2240
Short Tons Pounds 2000
Long Tons Short Tons 1.12
PRESSURE
Pounds per Square Inch Pascals 6.895 x 103
Pounds per Square Inch Kilograms per Square CM 7.03 x 10-2
Pascals Pounds per Square Inch 1.45 x 10-4
Kilograms per Square CM Pounds per Square Inch 1.422 x 101
TEMPERATURE
Centigrade Kelvin 1.0 + 273
Centigrade Fahrenheit 1.8 + 17.78
Fahrenheit Centigrade -32 x 0.555
Fahrenheit Kelvin -32 x 0.555 + 273.15
Page 74 of 111
8.0
b
Area = ab
9.0
h
bh
Area =
b 2
Area = πab
a b
(
Circ. = π 2 a 2 + b 2 )
a = 2.598a 2
Circ. = 2πr
r
or
d Circ. = πd
Area = πr 2
Page 75 of 111
c
Total Surface Area (S)
S = 2πr (r + h )
d
Volume
V = πr 2 h
h r or
c 2h
V=
4π
Page 76 of 111
INSPECTION
TERMINOLOGY
9.0 Inspection Terminology
GLOSSARY (Saudi Aramco Eng Encyclopedia)
angle testing An ultrasonic test method in which transmission is at an angle

to the test surface.
back reflection The ultrasonic signal received from the back surface of a
test object.
bleed outThe action by which liquid penetrants flow out of a

discontinuity, due primarily to capillary action and the blotting effect of
the developer.
blowhole A hole in a casting or weld caused by gas entrapped during

solidification.
blotting The action of a developer in drawing out liquid penetrant from a

surface discontinuity causing maximum bleed out for increased contrast and
sensitivity.
capillary action The tendency of certain liquid to travel, climb, or draw into
tight crack-like interface areas due to such properties as surface tension,
wetting, cohesion, adhesion, and viscosity.
Category D Fluid Service As defined in ASME/ANSI B31.3, a fluid service

in which all the following apply: the fluid handled is nonflammable, nontoxic,
and not damaging to human tissues as defined in Paragraph 300.2; the design
gage pressure does not exceed 1,030 kPa (150 psi); and (3) the design
temperature is from -29°C through 186°C (-20° F through 366°F).
Category M Fluid Service As defined in ASME/ANSI B31.3, a fluid service

in which the potential for personnel exposure is judged to be significant and
in which a single exposure to a very small quantity of a toxic fluid, caused by
leakage, can produce serious irreversible harm to persons on breathing or
bodily contact, even when prompt restorative measures are taken.
Page 77 of 111
cold crack A flaw that appears as a straight line, usually continuous
throughout its length, and generally singly. These cracks start at the
surface.
couplant A substance used between an ultrasonic transducer face and the
test surface to permit or improve transmission or reception.
crack A material separation that has a relatively large cross-section in one
direction and a small or negligible cross-section when viewed in a direction
perpendicular to the first.
defect A discontinuity whose size, shape, orientation, location, or properties
make it detrimental to the useful service of the part in which it occurs, or
which exceeds the accept/reject criteria of the particular design.
developer A finely divided material applied over the surface of a part to
help bring out penetrant indications.
discontinuity Any interruption in the normal physical structure or
configuration of a part such as cracks, laps, seams, inclusions, or porosity. A
discontinuity may or may not affect the usefulness of the part.
dry powder Finely divided ferromagnetic particles selected and prepared
for magnetic particle inspection by the dry method.
examination Applies to quality control functions performed by the
manufacturer, fabricator, or erector.
false indication An indication that may be interpreted incorrectly as a
discontinuity or a defect; a non-relevant indication.
filled crack A crack open to the surface but filled with some foreign
material, such as oxide, grease, etc.
flaw An imperfection, which may not be harmful. If harmful, it is a defect
or discontinuity.
flux lines Imaginary lines used to explain the behavior of magnetic fields.
fusion The complete joining of two parts in such a manner that loads are
effectively transferred across their common boundary.
hot crack A flaw that appears as a ragged dark line of variable width and
numerous branches. It has no continuity, may exist in groups, and may
originate internally or at the surface.
hot tear A fracture formed in a metal during solidification.
indication An response that requires interpretation to determine its
significance.
Page 78 of 111
inspection The process of examining and checking materials and parts for
possible defects, or deviation from acceptance standards.
interpretation The process of determining the nature of an indication.
magnet A material having the power to attract iron and other substances to
itself and exhibit polarity.
magnetic flux The total number of magnetic lines existing in a magnetic
circuit.
Magnetic discontinuity A break in the magnetic continuity of a part,
possibly caused by a defect.
Nondestructive examination Testing to detect internal, surface, or
concealed defects or flaws in a material using techniques that do not damage
the item being tested.
Non-relevant indications These are true indications produced by
uncontrolled or incorrect test conditions. They have no relation to
discontinuities that might be defects.
normal fluid service As defined in ASME/ANSI B31.3, a fluid service
pertaining to most piping covered by this Code, i.e., not subject to the rules
for Category D, Category M, or High-Pressure Fluid Service, and not subject
to severe cyclic conditions.
pores Small voids in the body of a metal.
porosity charts Standard charts for comparing porosity size, spacing, and
number in a given area.
pressure-containing weld A weld that joins two pressure-containing
components such as at a branch connection.
prods Two hand-held electrodes, which are pressed against the surface of a
part to make contact for passing magnetizing current through the metal.
radiography The use of radiant energy in the form of neutrons, x-rays or
gamma rays for NDE of opaque objects. It produces graphical records on
sensitized films, which indicate the comparative soundness of the object
being tested.
Reference radiographs A group of radiographs containing images of
discontinuities. They are used as comparison standards for material
acceptability.
severe cyclic conditions As defined in ASME/ANSI B31.3, those in which
SE, computed in accordance with Paragraph 319.4.4, exceeds 0.8SA (as
defined in Paragraph 302.3.5), and the equivalent number of cycles (N in
Page 79 of 111
paragraph 302.3.5) exceeds 7000; or other conditions which the designer
determines will produce an equivalent effect.
suspension The liquid bath in which ferromagnetic particles used in the wet
method are suspended.
void Discontinuity in which there is a physical separation between opposite

walls.
wet method The magnetic particle inspection method employing

ferromagnetic particles suspended in a light oil or water, which acts as a
vehicle.
Page 80 of 111
PRESSURE VESSELS
10.0 Vessels
PRESSURE VESSELS
Retirement Thickness:
It is advisable to use the safety instruction sheet (SIS) of the vessel
to determine the retirement thickness, as in most cases the calculation
may be complex.
Therefore, prior to a pressure vessel inspection, the inspector should
obtain a copy of the SIS for the equipment.
Thickness of Shell Under Internal
Pressure:
Cylindrical
Shell:
Choose the Greater of (1) and (2)

Below:
(1) t= PR P= SEt
SE - 0.6P R + 0.6t
or
(2) t= PR 2SEt
2SE + 0.4P R – 0.4t
or
Spherical
Shell:
(3) t= PR P= 2SEt
or
2SE – 0.2P R – 0.2t
t= Minimum thickness P= Design pressure, (PSI)

R= Inside radius S= Maximum allowable
stress value
of the material (PSI)
E= Joint efficiency
Page 81 of 111
Conditions for (1) above:
T Does not exceed ½ R or P does not exceed 0.385
SE

t Does not exceed ½ R or P does not exceed 1.25
SE
t Does not exceed 0.356 R or P does not exceed
0.665 SE
Thicknesses of shells under external pressure see ASME Sec. VIII Para.
UG-28)
(For conditions exceeding the above limits, see ASME sec. VIII
Div.1Appendix –1)
Thickness of Formed Heads Under Internal Pressure (Pressure on Concave Side)
Refer to the following figure for the typical types of heads and their dimensions
ASME SECTION VIII - DIVISION 1
t
D
t
h L
r L
D D t
(a) Ellipsoidal (b) Spherically Dished (c) Hemispherical

(Torispherical)
D
L
D
r
α
t
t D1
α
t
(d) Conical
(e) Toriconical
(Cone Head With Knuckle)
Page 82 of 111
(1)
Ellipsodial Heads
PD 2SEt
t= or
2SE - 0.2P R + 0.2t
Torispherical
(2)
0.885PL SEt
t= or
SE - 0.1P 0.885L + 0.1t

Hemispherical
(3)
PL 2SEt
t= or
2SE - 0.2P L + 0.2t
Conical
(4)
PD 2Set α
t= or
2 cos α (SE- 0.6P) D + 1.2t cos α
Toriconical
(5)
t for the conical section – use formula (4) above using Di in place of
D
Di = D – 2r (1 – cos α)
t for the knuckle section – use formula (3) above in which,

L= Di
2 cos α
Page 83 of 111
Conditions For the Above Formulae:
For (1) Half the minor axis = 1/4 of the ID of the head
above: skirt
Note: Approximate values of knuckle radius and spherical
radius of a 2.1 ellipsoidal head are 0.17D and 0.90D,
respectively.
For (2) Knuckle radius = 6% of inside crown radius

above:
Inside crown radius = outside Dia. of skirt
Note: For materials having tensile strength greater than
80,000 PSI, use S = 20,000 PSI at room
temperature.
For (3) t does not exceed 0.356 L

above:
or
P does not exceed 0.665 SE
For (4) Half apex angle α is not greater than 30 degrees

above:
Knuckle radius is neither less 6% of the OD of

For Toriconical Heads: the head skirt nor less than three times the
knuckle thickness
Note: Toriconical heads may be used when α ≤ 30 degrees,
but are mandatory for conical head design when α
exceeds 30 degrees
Page 84 of 111
Thickness of Heads Under External Pressure (Pressure on Convex Side)
Shall be calculated per ASME Sec. VIII Div. 1, Para. UG-33
Minimum Thickness of Nozzle Neck
In most cases, the retirement thickness of a nozzle neck shall be the

minimum thickness of a standard wall pipe (Listed in table 2 of ANSI B
36-10 less 12-½ %).
See ASME Sec. VIII Div. 1, Para. UG-45 for details.
Page 85 of 111
FITTINGS
11.0 Fittings
Welding Neck Flanges

150 LB. 300 LB. 400 LB. 600 LB.
Nom Outside Length Outside Length Outside Length Outside Length
Pipe Diam Of Thru Diam Of Thru Diam Of Thru Diam Of Thru
Size Flange Hub Flange Hub Flange Hub Flange Hub
O Y (1) O Y (1) O Y (2) O Y (2)
1 1 7 3 1 3 1
/2 3 /2 1 /8 3 /4 2 /16 For 3 /4 2 /16
3 7 1 5 1 5 1
/4 3 /8 2 /16 4 /8 2 /4 Sizes 4 /8 2 /4
1 4 1 /4 2 3/16 4 7 /8 2 7/16 3 1 /2 4 7 /8 2 7/16
1 1 /4 4 5 /8 2 1 /4 5 1 /4 2 9/16 and 5 1 /4 2 5 /8
1 1 /2 5 7
2 /16 1
6 /8 11
2 /16 smaller 1
6 /8 2 3 /4
1 1 3
2 6 2 /2 6 /2 2 /4 use 6 1 /2 2 7 /8
2 1 /2 7 2 3 /4 7 1 /2 3 600 Lb. 7 1 /2 3 1 /8
3 7 1 /2 2 3 /4 8 1 /4 3 1 /8 standard 8 1 /4 3 1 /4
3 1 /2 8 1 /2 2 13/16 9 3 3/16 9 3 3 /8
4 9 3 10 3 3 /8 10 3 1 /2 10 3/4 4
5 10 3 1 /2 11 3 7 /8 11 4 13 4 1 /2
6 11 3 1 /2 12 1/2 3 7 /8 12 1/2 4 1/16 14 4 5 /8
8 13 1/2 4 15 4 3 /8 15 4 5 /8 16 /21
5 1 /4
1 5 1
10 16 4 17 /2 4 /8 17 /2 4 7 /8 20 6
12 19 4 1 /2 20 1/2 5 1 /8 20 1/2 5 3 /8 22 6 1 /8
14 21 5 23 5 5 /8 23 5 7 /8 23 3/4 6 1 /2
1 1 3 1
16 23 /2 5 25 /2 5 /4 25 /2 6 27 7
1 1
18 25 5 /2 28 6 /4 28 6 1 /2 29 /41
7 1 /4
1 11 1 3 1
20 27 /2 5 /16 30 /2 6 /8 30 /2 6 5 /8 32 7 1 /2
22 29 1/2 5 7 /8 33 6 1 /2 33 6 3 /4 34 1/4 7 3 /4
24 32 6 36 6 5 /8 36 6 7 /8 37 8
1 1 1 1
26 34 /4 5 38 /4 7 /4 38 /4 7 5 /8 40 8 3 /4
30 38 3/4 5 1 /8 43 8 1 /4 43 8 5 /8 44 1/2 9 3 /4
34 43 3/4 5 5/16 47 1/2 9 1 /8 47 1/2 9 1 /2 49 10 5/8
3 1
36 46 5 /8 50 9 /2 50 9 7 /8 51 /43
11 1/8
42 53 5 5 /8 57 10 7/8 57 11 3/8 58 3/4 12 3/4
(1) The 1/16" raised face is included in “Length thru Hub ‘Y’.”
(2) The 1/4" raised face is not included in “Length thru Hub ‘Y’.”
Page 86 of 111
Y Y Y
O O O
Slip-On, Threaded, And Socket Type Flanges

150 LB. 300 LB. 400 LB. 600 LB.
Nom Outside Length Outside Length Outside Length Outside Length
Pipe Diam Thru Diam Thru Diam Thru Diam Thru
Size Hub Hub Hub O Hub
O Y (1) O Y (1) O Y (2) Y (2)
1
/4 3 1 /2 5
/8*t 3 3 /4 7
/8*t 3 3 /4 7
/8*t
3 1 5 3 7 3 7
/8 3 /2 /8*t 3 /4 /8*t For 3 /4 /8*t
1
/2 3 1 /2 5
/8 3 3 /4 7
/8 Sizes 3 3 /4 7
/8
3
/4 3 7 /8 5
/8 4 5 /8 1 3 1 /2 4 5 /8 1
1 4 1 /4 11
/16 4 7 /8 1 1/16 and 4 7 /8 1 1/16
1 1 /4 5
4 /8 13
/16 5 1 /4 1 1/16 smaller 5 1 /4 1 1 /8
1 1 /2 5 7
/8 1
6 /8 3
1 /16 use 6 1 /8 1 1 /4
2 6 1 6 1 /2 1 5/16 600 Lb. 6 1 /2 1 7/16
2 1 /2 7 1 1 /8 7 1 /2 1 1 /2 standard 7 1 /2 1 5 /8
3 7 1 /2 1 3/16 8 1 /4 1 11/16 1
8 /4 1 13/16
3 1 /2 1
8 /2 1 1 /4 9 1 3 /4 9 1 15/16
4 9 1 5/16 10 1 7 /8 10 2✜ 10 3/4 2 1/8✜
5 10 1 7/16 11 2✜ 11 2 1/8✜ 13 2 3/8✜
6 11 1 9/16 12 /21 7
3 /8✜ 1
12 /2 2 1/4✜ 14 2 5/8✜
1
8 13 /2 1 3 /4 15 3
4 /8✜ 15 2 11/16✜ 16 /21
3✜
10 16 1 15/16 17 1/2 2 5/8✜ 17 1/2 2 7/8✜ 20 3 3/8✜
12 19 2 3/16 20 1/2 2 7/8✜ 20 1/2 3 1/8✜ 22 3 5/8✜
14 21 2 1 /4 23 3✜ 23 3 5/16✜ 23 /43
3 11/16✜
1
16 23 /2 2 1 /2 25 1/2 3 1/4✜ 25 1/2 3 11/16✜ 27 4 3/16✜
18 25 2 11/16 28 3 1/2✜ 28 3 7/8✜ 29 1/4 4 5/8✜
20 27 1/2 2 7 /8 30 1/2 3 3/4✜ 30 1/2 4✜ 32 5✜
1
22 29 /2 3 1/8✝✜ 33 4✝✜ 33 4 1/4✝✜ 34 /41
5 1/4✝✜
24 32 3 1 /4 36 3
4 /16✜ 36 4 1/2✜ 37 5 1/2✜
26 34 1/4 3 3/8✝✜ 38 1/4 7 1/4✝✜ 38 1/4 7 5/8✝✜ 40 8 3/4✝✜
30 38 3/4 3 1/2✝✜ 43 8 1/4✝✜ 43 8 5/8✝✜ 44 1/2 9 3/4✝✜
3
34 43 /4 3 11/16✝✜ 47 /21 1
9 /8✝✜ 1
47 /2 9 1/2✝✜ 49 10 5/8✝✜
36 46 3 3/4✝✜ 50 1
9 /2✝✜ 50 9 7/8✝✜ 51 /43
11 1/8✝✜
42 53 4 ✝✜ 57 10 7/8✝✜ 57 11 3/8✝✜ 58 3/4 12 3/4✝✜
* Not available in Slip-on type.
✝ Not available in Threaded type.
✜Not available in Socket type.
Page 87 of 111
Q
O 1/
16
"
Blind Flanges
150 LB. 300 LB. 400 LB. 600 LB.
Nom Outside Outside Outside Outside
Pipe Diam Of Thick Diam Of Thick Diam Of Thick Diam Of Thick
Size Flange ness Flange ness Flange ness Flange ness
O Q (1) O Q (1) O Q (2) O Q (2)
1
/2 3 1 /2 7
/16 3 3 /4 9
/16 3 3 /4 9
/16
3
/4 3 7 /8 1
/2 4 5 /8 5
/8 For 4 5 /8 5
/8
1 4 1 /4 9
/16 4 7 /8 11
/16 Sizes 4 7 /8 11
/16
1 1 /4 5
4 /8 5
/8 1
5 /4 3
/4 3 1 /2 1
5 /4 13
/16
1 1 /2 5 11
/16 6 1 /8 13
/16 and 6 1 /8 7
/8
smaller
2 6 3
/4 6 1 /2 7
/8 use 6 1 /2 1
2 1 /2 7 7
/8 7 1 /2 1 600 Lb. 7 1 /2 1 1 /8
3 7 1 /2 15
/16 8 1 /4 1 1 /8 standard 8 1 /4 1 1 /4
3 1 /2 8 1 /2 15
/16 9 1 3/16 9 1 3 /8
15
4 9 /16 10 1 1 /4 10 3/4 1 1 /2
10 1 3 /8
15
5 10 /16 11 1 3 /8 11 1 1 /2 13 1 3 /4
6 11 1 12 1/2 1 7/16 12 1/2 1 5 /8 14 1 7 /8
8 13 1/2 1 1 /8 15 1 5 /8 15 1 7 /8 16 1/2 2 3/16
10 16 1 3/16 17 1/2 1 7 /8 17 1/2 2 1 /8 20 2 1 /2
12 19 1/2 1 1 /4 20 1/2 2 20 1/2 2 7 /8 22 2 5 /8
14 21 1 3 /8 23 2 1 /8 23 2 3 /8 23 3/4 2 3 /4
16 23 1/2 1 7/16 25 1/2 2 1 /4 25 1/2 2 1 /2 27 3
18 25 1 9/16 28 2 3 /8 28 2 5 /8 29 1/4 3 1 /4
20 27 1/2 1 11/16 30 1/2 2 1 /2 30 1/2 2 3 /4 32 3 1 /2
22 29 1/2 1 13/16 33 2 5 /8 33 2 7 /8 34 1/4 3 3 /4
24 32 1 7 /8 36 2 3 /4 36 3 36 4
26 34 1/4 2 38 1/4 3 1 /8 38 1/4 3 1 /2 40 4 1 /4
30 38 3/4 2 1 /8 43 3 5 /8 43 4 44 1/2 4 1 /2
34 43 3/4 2 5/16 47 1/2 4 47 1/2 4 3 /8 49 4 3 /4
36 46 2 3 /8 50 4 1 /8 50 4 1 /2 51 3/4 4 7 /8
42 53 2 5 /8 57 4 5 /8 57 5 1 /8 58 3/4 5 1 /2
Page 88 of 111
SAES-L-009 also lists standard Saudi Aramco drawings that provide
mandatory dimensional standards for specific size ranges, ratings, flange
types, and facings.
These standard flanges must be used as applicable within their defined

scopes, even if API-605, MSS-SP-44, or ASME/ANSI B16.47 has the same
designations.
These standard drawings are as follows:

NPS Range Class Type Facing Standard Drawing
26-60 150 WN RF AD-036634
26-60 300 WN RF AD-036991
26-48 300 WN RJ AC-036484
54-60 300 WN RJ AC-036437
30-48 400 WN RF AD-036698
26-48 600 WN RF AD-036673
26-48 600 WN RJ AC-036442
26-48 300 Lap RJ AC-036486
54-60 300 Lap RJ AE-036438
26-48 600 Lap RJ AC-036443
54-60 75 Blind RF AD-036696
where:
WN = Weld neck.
RF = Raised face.
RJ = Ring joint.
Lap = Lapped flange.
Blind = Blind flange.
Page 89 of 111
CODES
&
STANDARDS
12.0 Codes & Standards
Typical construction codes in use internationally are:
• American Society of Mechanical Engineers Boiler and Pressure Vessel
Code (ASME-BPVC).
• American Petroleum Institute (API 650- Storage Tanks)
• British Standards (BS5500 Pressure Vessels)
• AD-Merkblatt (German Pressure Vessel Code)
• TRD (German Boiler Code, normally read in conjunction with VGB
Directives).
• CODAP (France)
• Stoomwezen (Netherlands)
• ASME 31.1- Boiler Piping Code
• ASME 31.3 – Chemical Piping
• ASME 31.4- Gas transportation piping
• ASME 31.8- Liquid Hydrocarbon transportation piping.
The European codes are currently under review and the following product
standards will eventually supercede the existing National Standards:
• CEN/TC54 Unfired Pressure Vessels
• CEN/TC267 Industrial Piping
• CEN/TC269 Boilers.
Saudi Aramco normally uses the ASME-BPVC Construction codes such as

ASME VIII Division 1 and 2 for pressure vessels and ASME 1 for Boilers.
The main difference between ASME VIII Division 1 and 2 is that 1 currently
has a Factor of Safety (FOS) of four (under consideration to change to 3.5)
and 2 has a FOS of three. Most of the European codes are based on a FOS
of three. That is why ASME VIII Division 2 and the European Construction
codes normally stipulate higher quality materials, and in turn a greater level
of non-destructive testing. The ASME Construction Codes are supported by
other sections such as ASME V (Non-destructive Testing), ASME IX
(Welding), etc. When a vessel is constructed by an ASME registered
manufacturer, in accordance with the ASME code under the auspices of a
valid commissioned Authorized Inspector (National Board of Boiler and
Pressure Vessel Inspectors) the vessel can be stamped as being in
accordance with the ASME Code. Vessels not required to be code stamped
Page 90 of 111
(U) but are built using the ASME codes are said to be built “Generally in
accordance with the ASME Code”. This normally means they have followed
the design, materials, testing requirements but have not followed the Code
rules fully (i.e. no Authorized Inspector), these vessels are not ASME
pressure vessels and are not stamped, the U1 data form when completed will
lack the Authorized Inspectors agreement that it complies with the code
and acceptance is based on alternative wording.
Repairs or modifications to ASME pressure vessels that have seen service,

when such repairs or modifications are not under the auspices of an
Authorized Inspector means that the vessels are no longer ASME pressure
vessels but remain “pressure vessels generally built in accordance with the
ASME code” unless such repairs are conducted by an owner-user with “R”
stamp approval.
Typical codes and standards that address pressure equipment that has seen
service are:
• ANSI/NB-23 National Board Inspection Code

• API 510 Pressure Vessels.
• API 570 Process Piping.
• API 653 Storage Tanks.
Review of the SAES/SAEP and SAIP includes a number of documents that

reference the above documents and typical documents that the Inspector
should utilize during the course of his work include:
SAES-A-004 General Requirements for Pressure Testing

SAES-A-007 Hydrostatic Testing Fluids and Lay-up Procedures
SAES-A-206 Positive Material Identification
SAES-B-005 Spacing and Diking for Atmospheric and Low Pressure Tanks
SAES-D-001 Design Criteria for Pressure Vessels
SAES-D-100 Design Criteria of Atmospheric and Low Pressure Tanks
SAES-D-108 Storage Tank Integrity
SAES-D-109 Design of Small Tanks
SAES-E-004 Design Criteria of Shell and Tube Heat Exchangers
SAES-E-006 Design Criteria of Double Pipe Heat Exchangers
Page 91 of 111
SAES-E-007 Design Criteria of Air Cooled Heat Exchangers
SAES-E-014 Design Criteria of Plate and Frame Heat Exchangers
SAES-E-015 Design Criteria of Electric Heat Exchangers
SAES-F-001 Design Criteria of Fired Heaters
SAES-F-007 Design Criteria of Flares
SAES-H-001 Selection Requirements for Industrial Coatings
SAES-H-002 Internal and External Coatings for Steel Pipelines and Piping
SAES-H- Approved Saudi Aramco Data Sheets
002V
SAES-H-101 Approved Protective Coating Systems
SAES-H-101V Approved Saudi Aramco Data Sheets- Paints and Coatings
SAES-H-200 Storage, Handling and Installation of Pipe Externally Coated with
Fusion Bonded Epoxy or Polyethylene
SAES-H-201 General Specification for Over-The-Ditch External FBE
Coating of Field Girth Welds
SAES-H-203 Hand Applied Tape-Wrapping of Buried Pipe
SAES-H-204 General Specification for Applying Heat-Shrink Sleeves to
Coated Pipe
SAES-H- Approved Vendor Installation Procedures for Heat-Shrink Sleeves
204V
SAES-L-001 Basic Criteria for Piping Systems
SAES-L-002 Design Conditions for Pressure Piping
SAES-L-003 Design Stress Criteria for Pressure Piping
SAES-L-004 Pressure Design of Piping Components
SAES-L-005 Piping Material Specifications
SAES-L-006 Metallic Pipe Selection
SAES-L-007 Selection of Metallic Pipe Fittings
SAES-L-008 Selection of Valves
SAES-L-009 Metallic Flanges, Gaskets and Bolts for Low and Intermediate
Temperature Service
SAES-L-010 Limitations on Piping Joints
SAES-L-011 Flexibility, Support and Anchoring of Piping
SAES-L-012 Design of Piping Systems inside Plant Areas
SAES-L-022 Design of Wellhead Piping, Flowlines, Trunklines and Testlines
SAES-L-032 Material Selection of Piping Systems
SAES-L-033 Corrosion Protection Requirements for Pipelines/ Piping
SAES-L-041 Utility Piping Connections to Process Equipment
Page 92 of 111
SAES-L-042 Plant Utility Stations
SAES-L-043 Thermal Expansion Relief in Piping
SAES-L-044 Anchors for Cross-Country Pipelines
SAES-L-045 Scraper Trap Station Piping and Apparatus
SAES-L-046 Pipeline Crossings Under Roads and Railroads
SAES-L-047 Valve Boxes
SAES-L-050 Construction Requirements for Metallic Plant Piping
SAES-L-051 Construction Requirements for Cross-Country Pipelines
SAES-L-052 Hot Tap Connections
SAES-L-056 Pressure Testing of Plant Piping and Pipelines
SAES-L-060 Nonmetallic Piping
SAES-L-062 Technically Acceptable Class 04 Valve Manufacturers
SAES-L-070 Technically Acceptable Manufacturers of API 6A 10000 PSI
Gate Valves and Chokes
SAES-N-100 Refractory Systems
SAES-N-110 Installation Requirements- Castable Refractories
SAES-W-010 Welding Requirements for Pressure Vessels
SAES-W-011 Welding Requirements for On-Plot Piping
SAES-W-012 Welding Requirements for Pipelines
SAES-W-014 Weld Overlays and Welding of Clad Materials
SAES-W-015 Strip Lining Application
SAES-W-016 Welding of Corrosion Resistant Materials
SAES-W-017 Welding Requirements for API Tanks
SAES-X -400 Cathodic Protection of Buried Pipelines
SAES-X -500 Cathodic Protection of Vessel and Tank Internals
SAES-X -600 Cathodic Protection of Plant Facilities
SAES-X -700 Cathodic Protection of Onshore Well Casings
SAEP- 20 Equipment Inspection Schedule

SAEP- 306 Evaluating The Remaining Strength of Corroded Pipelines
SAEP- 308 Operations Inspection Unit Reviews
SAEP- 309 Inspection of Community and Operations Support Facilities
SAEP- 310 Pipeline Repair and Maintenance
SAEP- 311 Installation of Hot-Tapped Connections
SAEP- 312 PLIDCO Weld + Ends Couplings
SAEP- 313 PLIDCO Split Sleeves
SAEP- 314 Use of PLIDCO Smith Pipeline Repair Clamps
Page 93 of 111
SAEP- 315 Installation of Stopple Fittings
SAEP- 316 Performance Qualification of Coating Personnel
SAEP- 317 Testing and Inspection (T & I) of Shell & Tube Heat Exchangers
SAEP- 318 Pressure Relief Valve Program Authorization for
Installation, Deletion and Changes
SAEP- 319 Pressure Relief Valves- Routine Test, Inspection,
Quality Assurance and Regulation
SAEP- 321 Performance Qualification Testing and Certification of
Saudi Aramco Welders
SAEP- 323 Performance Qualification Testing of Contract
Welders and Brazing
SAEP- 324 Certification Review and Registration of Project Welders and
Brazers
SAEP- 325 Inspection Requirements for Pressurized Equipment
SAEP- 1131 Pressure Relief Valve Program Use of Form 3099A,
RV Authorization
SAEP- 1132 Instructions for Using the Relief Valve Stand
SAEP- 1133 Form 3750, Pressuring Relieving Device Valve Test Stand
SAEP- 1135 On-Stream Inspection Administration
SAEP- 1140 Qualification and Certification of Saudi Aramco NDT Personnel
SAEP- 1141 Industrial Radiation Safety
SAEP- 1142 Qualification of Saudi Aramco NDT Personnel
SAEP- 1143 Radiographic Examination
SAEP- 1144 Magnetic Particle Examination
SAEP- 1145 Liquid Penetrant Examination
SAEP- 1150 Inspection Coverage on Projects
00-SAIP-06 Pressure Test Requirements

01-SAIP-02 Retirement Thickness of In-Plant Piping
02-SAIP-01 Inspection of Positive Seal Coupling Systems
32-SAIP-11 Inspection of Air-Cooled Heat Exchangers
Page 94 of 111
NGL PIPELINE DEPT.
B31.8( 1)
WELLHEAD PIPING
SSD Fence
B31.4( 2) B31.4( 3)
B31.8(1)(4)(5) DF=0.72 DF=0.5 ON-PLOT
OFF-PLOT
DF=0.5(2)
ZV SWD WELL
B31.3(1) Water
RECEIVER
LAUNCHER
B31.3(1)
B31.4( 2)
FLARE STACK
zv
B31.3( 1) Flare Gas
B31.3(1)(5) B31.4(1)
Gas
zv
Oil PIPELINE DEPT.
Condensate ZV PROD. HDR.
B31.3
B31.4, GAS Wasia Well
DF=0.5 B31.3(5)
WATER+GAS
B31.3(1)
SPECTACLE PLATE UER Well
B31.8(2) B31.3
DF=0.5
FLOWLINE
ON-PLOT
OFF-PLOT(1)
B31.8(3)
DF=0.72(2)
FLOWLINE
WELLHEAD PIPING
Note: Water line to EWT, Sewer line to

B31.8(3)
pit, and Instrument air lines are
designed as per B31.3. DF=0.5( Class 1-3)
=0.4( Class 4 )
DF=0.72
OFF-PLOT ON-PLOT
PLOT LIMIT VALVE WELLHEAD
Page 95 of 111
Page 96 of 111
Page 97 of 111
SUPPORTS
13.0 Supports
Saudi Aramco Engineering Encyclopedia outlines the function and design of
different types of supports used for:
• Tanks
• Vessels
• Piping
Refer to sections MEX 10107 and 110.03 for background information.
Figure 1 shows different types of supports such as Rigid Supports,

Restraints, Stops and Guides. Figure 2 depicts Flexible or Resilient
Supports. Figure 3 shows anchors inclusive of concrete anchors.
Table 1 is a guide to commonly referenced drawings within Saudi Aramco
relating to supports and reference should always be made to the latest
revision. Typical drawings are attached.
Page 98 of 111
Table 1
Index Plant No Drawing No Sheet No Revision No Description

L/M 990 AD-036990 2 0 Metricated saddle details for large diameter unrestrained pipelines.
L 990 AD-036990 1 13 Saddle details for large diameter unrestrained pipelines.
L/M 990 AB-036774 1 7 Pipe ring girder details
S 990 AB-036453 1 2 Wellhead pipe supports and anchor at wellhead
L 990 AB-036555 1 7 Standard wear pads for unrestrained pipelines
L 990 AB-036530 1 8 Offset & portable pipe supports for unrestrained pipelines 16” and
smaller. (attached)
L 990 AB-036100 1 8 Ring girders for bolting to supports for 16” O.D through 32” O.D
Pipe.
L 990 AB-036207 1 10 Pipe spacings (attached)
L 990 AD-036697 2 0 Metricated standard maximum spans for above ground
unrestrained pipelines 14” and larger using wear pads or saddles.
L 990 AC-036697 1 2 Maximum spans for above ground unrestrained pipelines 14” and
larger using wear plates or saddles.
L/M 990 AE-036252 1 4 Corrosion bar wear support
RIGID SUPPORTS
SHOE SADDLE
BASE ADJUSTABLE
DUMMY SUPPORT TRUNNION
SUPPORT
RESTRAINTS/GUIDES
CHANNEL GUIDE SLEEVE GUIDE BOX-IN GUIDE

VESSEL
STOP WITH SHOE VERTICAL BOX-IN GUIDE

FLEXIBLE OR RESILIENT SUPPORTS
SLING TYPE PIPE PIPE HANGER

PIPE SUPPORT BEAM
HANGER SUSPENDED FROM SIDE
SUSPENDED BY RODS
OF STRUCTURE
LOAD AND
DEFLECTION
SCALE
VARIABLE LOAD SUPPORT
SMALL CHANGE IN EFFECTIVE LEVER ARM
LARGE CHANGE
IN EFFECTIVE
LEVER ARM CONSTANT LOAD SUPPORT
RELATIVE
CONSTANT LOAD
Page 101 of 111

ANCHORS
ANCHOR ANCHOR
BEARING SURFACE
BEARING
SURFACE
TYPICAL THRUST BLOCK FOR 90 TYPICAL THRUST BLOCK FOR 45 TYPICAL THRUST BLOCK FOR
DEGREE BEND OR ELBOW DEGREE BEND OR ELBOW TEE CONNECTION
BEARING
SURFACE
TYPICAL THRUST BLOCK FOR

END CAP
TYPICAL THRUST BLOCK FOR
REDUCER
Page 102 of 111

NON-DESTRUCTIVE
EXAMINATION
14.0 Non Destructive Examination
Nondestructive Testing
Saudi Aramco Engineering Encyclopedia outlines the basics of the various
methods and should be consulted for background information. A number of
Saudi Aramco Engineering Procedures (SAEP) exist controlling the
performance of nondestructive testing (NDT). Non-destructive Examination
(NDE) and Non-destructive Evaluation (NDE) are other frequently used
terms dependent on country and context.
Common abbreviations used for NDT methods are P.T (Penetrant Testing),
MT (Magnetic Particle Testing), RT (Radiographic Testing), U.T (Ultrasonic
Testing), ET (Electromagnetic Testing), V.T (Visual Testing), AET (Acoustic
Emission Testing), L.T (Leak Testing), NRT (Neutron Radiographic Testing),
IRT (Infra-Red Testing) and can be further sub-divided into sub-methods
such as WFMT (Wet Fluorescent Magnetic Particle Testing)
Current SAEP’s include:
• SAEP 1143 Radiographic Testing

• SAEP 1144 Magnetic Particle Testing
• SAEP 1145 Penetrant Testing
The listed SAEP’s outline how the particular method is to be applied within
Saudi Aramco and outlines all necessary steps to perform the test and
report the test result. Table 1 outlines the Acceptance Criteria for the
applicable SAEP’s and the Saudi Aramco form to be used. Figure 5 provides
guidance on how to interpret and evaluate radiographs.
Page 103 of 111

Table 1
NDT SAEP Acceptance Criteria FORM
Method
VT Future Refer Code Future
PT 1145 Figure 1 Figure 2
MT 1144 Figure 3 Figure 4
RT 1143 Posted in RT Viewing Room (Fig Figure 6
5)
Currently no SAEP’s exist for the performance of neither UT nor other

Non-destructive testing that are considered “advanced”.
Distinction needs to be made between manufacturing flaws (i.e. lack of
fusion, etc) and In-Service deterioration (i.e. Caustic cracking). For the
detection of manufacturing defects the type of NDT to be performed, and
the extent, is controlled by the applicable construction code. Currently, for
detection of in-service deterioration more latitude is available for the
extent and type of NDT to be performed. Flaws induced from service
normally initiate at manufacturing flaws.
In-Service Deterioration normally manifasts in three basic forms:

• Cracking (sulfide cracks, amine cracking, etc)
• Metal loss due to corrosion/erosion
• Change in Material Properties (embrittlement, etc)
No one NDT method is capable of detecting all types of flaws and

selection of an appropriate NDT method for the specific failure
mechanism is paramount. Assistance should be sought from the
appropriate Saudi Aramco specialist in the Dhahran NDT Unit.
Page 104 of 111

FIGURE 1- PT Acceptance Criteria
Liquid Penetrant Testing Acceptance Criteria
Code Rejection Criteria
API 1104 1. Linear Indications

Indications > 1/16" (1.6mm) shall be considered as relevant.
Relevant indications are rejectable if:
Evaluated as crater cracks or star cracks and >5/32" (4mm) in
length.
Evaluated as cracks other than crater cracks or star cracks.
Evaluated as IF and >1" (25.4mm) in total length in a continuous
12" (305mm) weld or >8% of the weld length.
2. Rounded Indications.
For evaluation, the maximum dimension of rounded indications
shall be considered. Indications are rejectable defects if:
Individual indication >1/8" (3.2mm) or 25% of the thickness of
the thinner member, whichever is less.
Distributions of scattered rounded indications exceed the
concentration of API 1104, Figures 18 or 19.
Clustered rounded indications >1/2" (12.7mm) are present.
Combined length of clustered indications > 1/2" in any 12"
(305mm) of weld.
Any individual indication in a cluster >1/16" (1.6mm).
ANSI/A Indications > 1/16" (1.6 mm) shall be considered as relevant

SME 1. Linear Indication: Any Crack or linear indication
B31.1 2. Rounded Indications
& Indications with dimensions > 3/16" (4.8mm)
ANSI/A Four or more rounded indication in a line separated by 1/16"
SME (1.6mm) or less edge to edge.
B31.3 Ten or more rounded indication in any 6 sq. in. (3870mm2) of
surface with the major dimension of this area not to exceed 6 in.
(150mm).
Page 105 of 111

ASME Indications > 1/16" (1.6 mm) shall be considered as relevant
Section The following Indications shall be rejectable:
VIII, 1. Relevant linear indication > 1/16" (1.6mm)
Div 1 2. Relevant rounded indications > 3/16" (4.8mm)
3. Four or more rounded indications in a line separated by 1/16"
(1.6mm) or less (edge to edge).
AWS An Acceptance/Rejection criterion is dependent on service

D1.1 condition. Refer to the relevant project engineer or the
Inspection Department.
Page 106 of 111

Figure 2 PT Form
Liquid Penetrant Examination Request & Report Form
Log No. B.I. No. J.O. No. Plant No. Plant Name Contractor
Location/Kilometer Reference Aramco Rep. Unit Requested by: Phone: Date:
Technician Level Code / Acceptance Criteria Material Type Material Form Sch. / Thickness
Liquid Penetrant System: Penetrant Mfg Penetrant Batch No. Penetrant P/N Remover P/N. Developer P/N.
A-1____A-2____A-3____
B-1____B-2____B-3____
Surface Temperature White Light Intensity UV Light Intensity UV Light Model No. UV Meter Material Form
Model No.
Surface Condition / Part Description
Item Drawing No. Equipment P/N Weld Welder Exam Results REPAIR DEFECT
No. Line Reference. No. Symbol LOCATION TYPE & SIZE
ACC REJ
Interpretation by: (print) Badge No. Signature: Date:

________________________________________
PT Level II / PT Level III
NOTES:
1. All blanks are to be filled in or marked N/A (not applicable).
2. Examination performed by Level I require a sign-off by Level II or Level III.
Page 107 of 111

Figure 3 – MT Acceptance Criteria
1 ANSI/ASME B31.1 Power Piping
The following relevant indications are unacceptable:
1.1 Any cracks or linear indications.
1.2 Rounded indications with dimensions greater

than 3/16 inch (4.8mm).
1.3 Four or more rounded indications in a line

separated by 1/16 inch (1.6 mm) or less edge to
edge.
1.4 Ten or more rounded indications in any 6 square

inches (3870 mm²) of surface with the major
dimension of this area not to exceed 6 inches
(150 mm) with the area taken in the most
unfavorable location relative to the indications
being evaluated.
2 ASME B31.3 - Chemical Plant and Refinery Piping
Any cracks or linear indications are unacceptable.
3 ASME Section VIII, Division 1
3.1 Indications with any major dimension greater

than 1/16 inch (1.6 mm) shall be considered
relevant. All surfaces to be examined shall be
free of:
3.2 Relevant linear indications
3.2.1 Relevant rounded indications

greater than 3/16 inch (4.8 mm).
Page 108 of 111

3.2.2 Four or more rounded defects in a
line separated by 1/16 inch (1.6
mm) or less (edge to edge) except
where the specification for the
material establishes different
requirements for acceptance so far
as defects are concerned.
4 API 1104 - Welding of Pipelines and Related Facilities
Any indication with a dimension greater than 1/16 inch

(1.6 mm) shall be considered relevant. Relevant
indications shall be unacceptable when any of the
following conditions exist:
4.1 Linear indications evaluated as crater cracks or

star cracks, which exceed 5/32 inch (3.96 mm)
in length.
4.2 Linear indications evaluated as cracks other

than crater cracks or star cracks.
4.3 Linear indications evaluated as incomplete

fusion (IF) and exceed 1 inch (25.4 mm) in total
length in a continuous 12-inch (304.8 mm) length
of weld or 8% of the weld length.
4.4 Individual or scattered porosity (P) shall be

unacceptable when any of the following
conditions exists:
4.5 The size of an individual pore exceeds 1/8 inch

(3.17 mm) or 25% of the thinner of the nominal
wall thickness joined.
4.6 Cluster porosity (CP) in any pass except the

finish pass shall be unacceptable when any of
the following conditions exist:
Page 109 of 111

4.7 An individual pore within a cluster exceeds 1/16
inch (1.6 mm).
4.8 The CP diameter exceeds 1/2 inch (12.7 mm).
4.9 The aggregate length of CP in a continuous 12-

inch (304.8 mm) length of weld exceeds 1/2
inch (12.7 mm).
Page 110 of 111

BASIC GUIDE TO EVALUATING AND INTERPRETING RADIOGRAPHS Oct 5th, 1998
S C A L E JO or BI Number?
Component, Vessel or Piping Identification?
SAEP-1143 Seam or Weld Identification?
RADIOGRAPHIC R1 for Repair (if applicable)?
EXAMINATION
C O D E
Cutouts NW1 (if applicable)?
(30-SEP-98) Date of Radiography?
Weld Thickness?
Pipe Diameter and Thickness?
C O R R O S I O N
Material Type?
Maps of Location Markers (if applicable)?
SAEP-1141 DEALING WITH THE CORRECT RADIOGRAPH? Film Brand and Designation?
INDUSTRIAL No of Films per Cassette?
RADIATION
RT REPORT ACCOMPANIES RADIOGRAPH?
FORM 4719-A-ENG (9/98) USED? Single or Double Wall Exposure?
SAFETY Single of Double Wall Viewing?
No of Exposures?
Isotope used or Max X-Ray voltage used?
VIEWING FACILITIES ACCEPTABLE? Effective Focal Spot Sizes
SUBDUED BACKGROUND LIGHTING? Minimum Source to Film Distance?
RADIOGRAPHIC VIEWER WITH SUFFICIENT LIGHT Welder Symbol?
OUTPUT VIA VARIABLE LIGHT SOURCE? (ISO 5580-85)
NO INTERFERING LIGHT FROM OUTER EDGES OF Defect Types?
FILM? Acc/Rej?
CALIBRATED DENSITOMETERS AS PER ASTM SE- Technician Name, Badge # & Signature?
1079?
DENSITOMETER CHECKED AGAINST CALIBRATED Technician Certified and to Level ?
DENSITY STRIP PRIOR TO USE? RTFI Name, Badge #, Signature, Certified &
Level?
Check no artifacts, fogging, etc in area of

interest.
REVIEW RT REPORT
Check for Excessive Backscatter ( light image
of "B" on dark background rejectable).
Check if "F" is next to IQI (If applicable- it

signifies it has been placed Film side).
Check Geometric Unsharpness (Ug).
CHECK QUALITY OF Check IQI WIre Identification, placement,

RADIOGRAPH amount, material type, no damage, and required
wire is visible.
Check Density adjacent to required wire on IQI.
Check Density Variation -15% to +30%.
View Area of Interest.
Identify Relevant Flaws, Slag, Cracks, etc.
INTERPRET RADIOGRAPH Size Relevant Flaws, diameter, length, width,

location, seperation distances, isolated, etc.
Compare Flaw Type with Relevant Code Edition

and Accept/ Reject.
Compare Flaw dimensions with Relevant Code
Edition and Accept/ Reject.
EVALUATE RADIOGRAPH Final acceptance of radiograph by SA Certified
TO ACCEPTANCE CRITERIA RTFI.
(APPENDIX I OF SAEP-1143)
Document Results, Date, Sign, Badge Number,

Level.
Communicate & Distribute Results, File Results
and store Film.
REPORTING
Page 111 of 111

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forms/GenlInsp/
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Wednesday, September 15, 1999 10:09 AM 25600 INSP-9000 Engineering Inspection

Hot Tap.xls
Monday, June 12, 2000 7:11 AM 16384 INSP-9001 Daily Planning
Sheet.xls
Tuesday, December 07, 1999 1:17 PM 35328 INSP-9002 Request for 100% X-Ray
in Lieu of Hydrotest.xls
Wednesday, September 15, 1999 10:12 AM 39424 INSP-9003 Battery Data Record.xls
Saturday, July 10, 1999 6:31 PM 13824 INSP-9004 Unfired Pressure Vessel
External Inspection.xls
Saturday, July 10, 1999 6:32 PM 13824 INSP-9005 Tank-In Service
Inspection.xls
Monday, June 05, 2000 11:01 AM 21504 INSP-9006 Leak Repair Report.xls
Saturday, July 10, 1999 6:43 PM 13824 INSP-9007 Tank Out-of-Service
Inspection.xls
Tuesday, April 18, 2000 3:11 PM 38400 INSP-9008 Pressure Test
Report.xls
Monday, January 22, 2001 1:12 PM 46592 INSP-9008_Form_(Template).doc
Wednesday, September 15, 1999 10:18 AM 44032 INSP-9009 Radiographic Request
Form.xls
Saturday, July 10, 1999 7:01 PM 58880 INSP-9010 Weld Inspection
Report.xls
Wednesday, September 15, 1999 12:49 PM 40960 INSP-9011 Ultrasonic Testing
Inspection.xls
Saturday, July 10, 1999 7:09 PM 13824 INSP-9012 Equipment Inspection
Schedules.xls
Wednesday, September 15, 1999 12:59 PM 37888 INSP-9013 Frequent Inspection.xls
Wednesday, September 15, 1999 1:00 PM 20480 INSP-9014 Vessel Inspection.xls
Sunday, December 12, 1999 7:26 AM 133120 INSP-9016 Landing Base.xls
Saturday, July 10, 1999 7:28 PM 54272 INSP-9017 Ultrasonic Request.xls
Saturday, July 10, 1999 7:31 PM 56832 INSP-9018 Off-Plot Piping Repair
Priority.xls
Monday, June 12, 2000 8:50 AM 18432 INSP-9020 Design Job Request.xls
Saturday, July 10, 1999 8:01 PM 75776 INSP-9021 Blank Isometric
Drawing.xls
Monday, June 12, 2000 8:50 AM 30720 INSP-9022 Thickness Survey &
Recommendations.xls
Wednesday, September 15, 1999 1:05 PM 40448 INSP-9024 Coating Survey.xls
Saturday, June 30, 2001 8:19 AM 53248 INSP-9025-1 RV audit1.doc
Saturday, June 30, 2001 8:16 AM 65536 INSP-9025-2 RV audit2.doc
Wednesday, September 15, 1999 1:07 PM 37376 INSP-9027 Pipeline Hydrotest
Data.xls
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Tuesday, December 07, 1999 1:30 PM 38912 INSP-9030 Aramco Inspection

Procedures-Liquid Penetrant Exam..xls
Wednesday, September 15, 1999 1:10 PM 44032 INSP-9031 Aramco Inspection
Procedures-Magnetic Particle Exam..xls
Tuesday, December 07, 1999 1:31 PM 38400 INSP-9033 Vessel Internal
Inspection Summary.xls
Wednesday, September 15, 1999 1:12 PM 37376 INSP-9034 Vessel Daily T&I
Inspection Status.xls
Wednesday, September 15, 1999 1:13 PM 76288 INSP-9035 Ultrasonic Testing
Inspection Report-Multimapping.xls
Wednesday, September 15, 1999 9:05 AM 40960 INSP-9036 Change of Revalidation
Hydrotest Interval.xls
Saturday, April 15, 2000 7:43 AM 25088 INSP-9037 Scraper Run Report.doc
Wednesday, September 15, 1999 1:14 PM 35328 INSP-9038 Coating Environment
Record Sheet.xls
Monday, May 17, 1999 10:07 AM 26624 INSP-9039 Pressure Relief Valves
External Inspection.doc
Tuesday, June 25, 2002 4:02 PM 511488 INSP-9039A Pressure Relief Valves
External Inspection.doc
Wednesday, January 10, 2001 11:25 AM 270336 INSP-9039B PRV Ext Insp
Existing.dot
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Southern Area Corrosion Control

First Draft: July 18, 1999.

D. Boult SAPED/TSU Chairperson

A. Brodie SACCID Member

N. Smith SACCID Member

Gopal SACCID Member

A.K. Al Hamad SACCID Member

A.S. Al Kishi SACCID Member

Compiled by D. Boult ~ SAPED/TSU (Tel: 576-6147)

This handbook is designed to give the field Inspector useful

The information contained was taken from various sources

Any inaccuracies or discrepancies should be reported to the

If there are any omissions or areas not covered give the

The Handbook Team.

1.0 Paints & Coatings

2.0 Inspection Reports

3.0 Hydrostatic Testing

4.0 Welding Procedures

5.0 Inspection Tools

6.0 Safety Guidelines

8.0 Conversion Factors

9.0 Inspection Terminology

12.0 Codes & Standards

14.0 Non Destructive Examination

8.2 Visual Inspection

The Inspector shall verify that the surface preparation

A minimum number of 6 readings shall be taken on each field joint coating to

100% of the coated girth weld surface area shall be holiday

The material for patch coating shall be supplied or approved by the

6.3.1 Damaged FBE coating shall be repaired as follows:

6.3.1.1 Areas smaller than 1450 sq mm - use thermal melt sticks or an

6.3.1.3 Areas larger than 0.2 sq m - use APCS-113.

6.3.2 Damaged PE coating shall be repaired as follows:

6.3.2.2 Holidays larger than 150 mm in any direction (including close

5.2.5 Internal coatings in dead-leg areas shall be holiday free.

5.3 Internal Coatings, Various Services

Categories Appr'd Coatings Syst Area to be Coated/

5.3.1 Water APCS-103 APCS-103 APCS-100, 101, & 102

5.3.2. Water Oil APCS-100 APCS-103 For APCS-2A the allowable

Categories Appr'd Coatings Syst Area to be Coated/

5.4.1 Buried APCS-104 APCS-109 APCS-106 may only be

APCS-113 may be used on

5. 4. 2 Buried APCS-104 APCS-113 Use APCS-22 if the

5. 4. 3 Buried APCS-104 APCS-113 Use APCS-22 if the

5. 4. 5 Above Not Not

5. 4. 6 Buried See See Coat concrete anchors in

5.6 External Pipe Coatings, In-Plant

Categories Appr'd Coatings Syst Area to be Coated/

5. 6. 3 Insulated See See No coating needed where

5. 6. 5 Industrial APCS-1A APCS-26A

5.2.2 The use of reclaimed slag abrasives is prohibited. The use of

5.2.3 The use of sand as a blasting abrasive shall be permitted only as

5.2.3.2 New construction, exterior surfaces. Sand meeting the

5.2.3.3 Spot repairs (Maintenance and New Construction) exterior

5.2.3.4 Sand shall not be used as a blasting abrasive for immersion

1. Physical characteristics: The sand shall be clean, dry, and free of

6. Appearance: No discernable contaminants shall remain on the steel substrate

Table II - Calculating Dft, Wft, And Theoretical Coverage

No solvent added: DFT = WFT x % Solids by Volume

Plant Name: Plant Number: Date: //

Replaced: YES/NO New Type: Date Installed: //_

See reverse for vessel drawing Date: //_